CU-1
Modular Architecture
Investment Case
A proposal to approve US$325,000 programme investment to develop and manufacture a fully ChargedUp-owned station — replacing the current Relink-supplied product with an independently designed, lower-cost, IP-owned alternative manufactured at Shield Works in China.
How We Got Here
ChargedUp currently purchases its portable power bank rental stations from a third-party manufacturer (Relink). Shield Works was engaged to reverse-engineer the existing product and build a route to an independently owned, lower-cost, scalable alternative manufactured in China.
Three successive quotation rounds have established the cost baseline and informed the design of CU-1 — the first ChargedUp-owned, architecture-optimised station:
The Investment Decision
Approve US$325,000 total programme investment to develop and manufacture a fully ChargedUp-owned station (CU-1), replacing the current Relink-supplied product.
What the Numbers Show
All comparisons below are on a like-for-like basis at 1,000 units EXW. The Relink column shows what ChargedUp currently pays its existing supplier.
| @1k units EXW | Relink | Q01 | Q02 | CU-1 Target | vs Q02 | vs Relink |
|---|---|---|---|---|---|---|
| Station only (excl. batteries) | $238.79 | $202.39 | $198.10 | ~$163 | –$35 | –$76 |
| Station + 5× power banks | $292.59 | $254.91 | $250.62 | ~$215 | –$36 | –$78 |
| Tooling | N/A | $205,800 | $147,054 | ~$150,000 | – | – |
| Payback (units) | – | ~8,648 | ~7,435 | ~4,000 | Target zone |
How the $78 Saving Is Achieved
ChargedUp currently pays Relink ~$293 per station including batteries. The CU-1 target is ~$215 — a saving of ~$78 per unit (~27%). This saving is built from two distinct layers.
Roughly ~$40 was already validated through the Q01/Q02 like-for-like sourcing exercise: same architecture as Relink, independently manufactured in China. The remaining ~$35 comes from the CU-1 architecture redesign — replacing the high-cost 4G comms/control board (SIMCom SIM8918EA at ~$91/unit) with a modular stack (separate BMS + 4G + Wi-Fi modules, paired with an Android screen for UI/control), reducing comms cost to ~$55–$60. A further ~$5–$10 comes from BOM optimisation and DFM/DFA refinements. This is an architecture-level change, not speculative supplier pressure.
The Numbers Are Solid
We have a high level of confidence in both the total programme investment and the CU-1 unit cost target. The Q02 baseline ($198/$251) was built from a full component-level teardown with multi-supplier quotes at volume — this is verified, not estimated. The total investment (~$325k) is individually costed from supplier quotes and Shield Works programme history, with every major line item validated.
The CU-1 ~$35 unit cost reduction is based on a proven modular architecture already deployed in the market, not speculative supplier negotiation. The specific module pricing will be validated as part of CU-1 sourcing, but the architecture direction and indicative savings have been confirmed through direct supplier engagement and our electronics team's assessment. The ~4,000 unit payback target follows directly from achieving the CU-1 unit cost — a significant improvement from the Q01 (8,648 units) and Q02 (7,435 units) baselines.
The Dec 2026 mass production timeline is achievable provided sign-off occurs in Mar 2026, with certification and electronics development running in parallel. The gating risk is the Stripe reader procurement route, which requires an early decision.
Shield Works confirms that its own associated fees and overheads — specifically the SW Development fee ($72,000) — are locked in at the figures quoted above and will not increase, even if the project timeline extends beyond the planned 9-month duration. This commitment removes the risk of cost overrun on SW's side of the programme. Third-party costs (tooling, certification, firmware) are separately quoted from suppliers and are already validated to a high confidence level.
What $325k Delivers
A fully ChargedUp-owned, independently manufactured station with premium industrial design, modular architecture for lower unit cost and easier servicing, full IP ownership, and a scalable manufacturing line at Shield Works in China.
The product is backward-compatible with the existing Relink power bank fleet in the UK, meaning no disruption to the installed base during transition.
| Investment Item | Cost (USD) | Notes |
|---|---|---|
| Tooling (injection moulding) | $150,000 | Locked-in (confirmed as per Relink current model architecture) |
| SW Development (9 months) | $72,000 | Locked-in (see SW fee-lock guarantee above) |
| Firmware | $60,000 | Verified SW Outsource Quotation |
| Certification (EMC/RED) | $18,000 | Verified SW Quotation |
| Assembly Fixtures + Jigs | $15,000 | Locked-in (SW fee-lock guarantee) |
| Prototyping | $10,000 | Verified SW Quotation |
| Total | $325,000 | Range: $325k–$350k depending on final scope |
Programme Timeline
| Milestone | Target Date | Notes |
|---|---|---|
| Project sign-off + ID lock | Mar 2026 | Design and architecture direction confirmed |
| DFM/DFA + quotation complete | Jun 2026 | Final BOM, locked cost baseline |
| Tooling + certification complete | Sep 2026 | T1 parts approved; certs submitted |
| Pilot run | Oct–Nov 2026 | Production validation, QC sign-off |
| Mass production + shipment | Dec 2026 | First container dispatched to UK |
Three Risks to Watch
Recommendations
The baseline is verified. The cost-down pathway is defined. Ready for sign-off.
Next step: review call to confirm CU-1 direction, then formal project approval.
I have personally reviewed the CU-1 programme plan and costings in full. The figures presented in this proposal are grounded in validated supplier quotes, a complete component-level teardown, and direct engagement with our electronics and sourcing teams. I am confident in the numbers, and Shield Works is committed to delivering this programme within the scope and budget outlined above. We stand behind this proposal and are ready to move immediately on sign-off.