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48V Waterproof Electrical Connector (2020)

Kai Concepts LLC, Alameda, California

High Performance Sports Equipment

Conceptual Design, Prototyping, Injection Molding, Testing


Kai Concepts is developing a premium electric foiling surfboard or e-foil which is equipped with hydrofoils and an electric motor. Engineering Design Lab was tasked to design a waterproof, high-current blind-mating connector.


The design is for a 48V connector that can handle up to 150A of current and can be connected in a partially wet state, if necessary, while also self-aligning with the socket located on the battery module. The design features user-replaceable electrical contacts and maintains its waterproof nature even while the contact pins are removed.


Tomek Bartczak was awarded a US Patent (US 10,946,939 B1) for the design in 2021 and the unit is now being mass-produced.

Client Testimonial:

I highly recommend Tomek and the team he assembled at his Engineering Design Lab for any design challenge but particularly those tasks that require skills at the intersection of traditional engineering disciplines. Tomek genuinely loves his craft as an engineering designer, and that enables him to come up with creative solutions, backed by analysis. Additionally, with his detail-oriented side - he sees his designs through from prototyping, to EVT, DVT, PVT and all the way to mass production. Tomek quickly acclimatized himself with our team and its dynamic, and the nuances of the project. He worked in a flexible manner, integrated well with existing team and provided top notch engineering services on a day by day basis.

Dmitri Stepanov, MASc, P.Eng
Product Manager
Kai Concepts LLC

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