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Wattsun Pop-up Power B.V., founded in 2016, aims to provide sustainable mobile energy solutions in places where the traditional power grid is not accessible. Their innovative products offer electric power in remote areas as an alternative to noisy and inefficient generators. Wattsun has developed a portable plug-and-play battery system that allows users to stack energy, similar to Lego blocks, providing continuous power at any location. Wattsun’s system is quiet, clean and emission-free, contributing to a greener environment by eliminating carbon dioxide, nitrogen and particulate emissions.
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Wattsun’s successful mission has resulted in a partnership with Coldplay, among others. To reduce the use of fossil fuels at their concerts, while raising awareness and making a mark in the events and culture sector. Moreover, Wattsun’s systems are widely used in the construction, landscaping and film industry. ManGo was contracted by Wattsun to critically evaluate where optimizations were possible in their product range, consisting of the Dock (the base station) and the Pack (supplementary energy). ManGo assisted Wattsun in improving cost efficiency and assembly, making the product more suitable for scaling up.
ManGo was commissioned to critically analyze the portable battery system and identify optimizations, with the aim of making the Wattsun more user-friendly, robust and cost-efficient. From our development process, the following improvements were eventually made:
As part of our optimization process, ManGo Product Design executed comprehensive Computational Fluid Dynamics (CFD) analysis to address one of the key challenges in the Wattsun Stack, ensuring efficient cooling within the compact, portable design. For outdoor battery systems like the Wattsun, maintaining proper airflow is critical to prevent overheating, especially when the product must withstand harsh environmental conditions. Our CFD simulations helped us precisely model the internal air circulation, ensuring that the components stay cool while housed within an enclosure that requires a high IP-rating to protect against rain, wet terrains, and dust. The need to balance effective cooling with rugged environmental protection was a complex task, and our analysis allowed us to optimize the airflow design without compromising the product’s durability or operational efficiency in demanding outdoor settings.
In the conceptual phase, ManGo started with a detailed analysis of the Wattsun’s existing design. We closely studied the 3D CAD models and disassembled and reassembled samples of the product to gain a deep understanding of the structure. During this process, sub-issues were identified and presented to the client. Solutions were developed through close collaboration within our multidisciplinary team, consisting of designers and mechanical engineers, during several brainstorming sessions. Promising solutions were then modelled in 3D CAD and converted into prototypes in our own workshop, which underwent extensive testing and optimization before going into production.
See more sustainable equipment developed by ManGo Product Design:
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