Form design registered, and partially prototyped - initially, I faced structural challenges that demanded meticulous problem-solving and technical engineering to overcome while preserving the integrity of the design. Addressing the issue of poor mating parts and inadequate tolerances, I rectified the tap's instability caused by an excessively heavy head, which led to compromised sealing by the  O-rings - tiger tolerancing striking a balance between something structurally strong but remaining easy to manufacture by hand. 

Given the limitations of milling,  electrical discharge machining had been opted for, this was inadvertently leading to minor leaks due to electrical pathways perforating the water conduits. To circumvent this, I implemented a cost-effective boring process, effectively removing excess weight while ensuring precise machining to maintain structural integrity.

In the realm of electronics, the existing two-board PCB setup posed both financial and quality concerns - connections are always the most vulnerable parts. Collaborating closely with the Sr electrical engineer, we came to a physical solution that could optimize their PCB design, streamlining it into a single board configuration, allowing for secure potting and sealing of the electronics within the tap head.

Liaising with suppliers, I orchestrated the complex journey from raw components to the potted assembly; developing bespoke jigs and fixtures to facilitate seamless potting operations, design of rubber sealing components played a pivotal role in securing the parts during potting, mitigating the risk of electrical short-circuiting and ensuring a watertight seal for the internal components.

Dedicated to creating a versatile and independent product that can be installed in many different install situations, I meticulously curated a comprehensive Kit of parts using a selection of electronic components, ranging from power cables to IP fitting connectors, battery banks, and transformers. I meticulously designed various interface adapters tailored to different installation scenarios, complemented by the precision-turned brass components for industry-standard mountings.