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How the Apple Watch Ultra became our biggest challenge
July 18, 2023
P erfection. A goal that is often strived for but rarely actually achieved. At BandWerk, our philosophy is that every product, every order only leaves our premises when it is truly flawless. Every piece of feedback from our customers is carefully analyzed and serves as the basis for continuous improvements.
Since the brand was founded in 2015, we have been committed to this philosophy and have perfected every aspect of our production, from the selection of materials to shipping. Whether it is finding the best tanneries for our high-quality leather or choosing the right paper for our delivery notes to provide a pleasant feeling, we pay attention to every detail.
But in 2022, we faced an unexpected challenge: the Apple Watch Ultra. Our trusted overseas manufacturers, who had been producing excellent adapters - the connecting parts between the strap and the Apple Watch - for us for years, quickly delivered an updated version for the new watch.
But something was different. The adapters didn't fit into the watch case as seamlessly and tightly as we were used to, and despite our best efforts, we couldn't figure out why.
We were unable to live up to our claim to perfection – a minor catastrophe.
Vincent (Co-Founder)
"The stability of the adapter depends on three factors: the overall form factor of the adapter housing, the precise size of the center oval latch, and the correct size of the two rubber bumpers. Despite adjusting these factors, we were unable to achieve a perfect fit."
Vincent (Co-Founder)
"The stability of the adapter depends on three factors: the overall form factor of the adapter housing, the precise size of the center oval latch, and the correct size of the two rubber bumpers. Despite adjusting these factors, we were unable to achieve a perfect fit."
The plan
A change in strategy was needed. Together with the company Holocreators, which specializes in extremely precise 3D scans of product components, we decided to first create a solid foundation.
To be on the safe side, we scanned everything that could help us design the adapters, including an Apple Watch Ultra and several original Apple bands.
With the scan files ready a few days later, our internal design team got to work and created a completely new adapter design that was individually tailored to our requirements. The concept was perfect on paper, but would it hold up in production?
Our adapter design for the Apple Watch Ultra: Should this solve the problem?
A detour to China
To ensure that the production process ran smoothly, we first sent Flo, our supply chain manager, to Hong Kong to monitor the production progress.
As luck would have it, he was already in Asia anyway. In fact, we surprised him in the middle of his Vietnam vacation by asking him to check on things in Hong Kong.
Day 1 in Hong Kong: Before you can get started, your holiday wardrobe must first make way for an appropriate business outfit.
It was a happy coincidence that brought Flo and Michael together. Flo had barely moved into his hotel room and settled in when he met Michael.
Michael, who had been living in China until recently, was in Hong Kong at the time waiting for his visa to enter mainland China. He planned to take care of some bureaucratic matters in Beijing.
While Europeans do not need a visa to enter Hong Kong, one is required to enter mainland China - and this can take several days or even weeks, especially in times of Corona.
Michael is fluent in Chinese and offered to assist Flo with any language barriers and help navigate the bureaucratic maze that sometimes accompanies international business travel.
First prototypes
The first personal meeting with our Chinese manufacturer took place at a trade fair in Hong Kong. Our producer had a stand there and offered to bring the first adapter prototypes so that Flo could inspect them.
Unfortunately, these first samples did not quite meet our high quality standards: they still had a little play and the surface finish was not quite perfect. Fortunately, our manufacturer was extremely cooperative and suggested that Flo could personally accompany the further development process at the factory in Shenzhen, China, in order to speed up the process and ensure quality.
Flo (Supply Chain Manager)
“Sometimes it is best to monitor production on site in order to be able to give direct feedback and thus not lose time in product optimization.”
Flo (Supply Chain Manager)
“Sometimes it is best to monitor production on site in order to be able to give direct feedback and thus not lose time in product optimization.”
Crossing the border
The trip to Shenzhen turned out to be an adventure of a different kind. Although Flo did not have a visa, he was assured that a 5-day visa would be applied for for him at the border. Normally this is a straightforward process, but the current zero-COVID policy put a stop to our plans.
After hours of Covid tests and visa formalities, he finally received the brief answer: "No Entry - Sorry" . The reason for this? No one could really explain, only that he should probably try again at another border crossing.
So we headed back to Hong Kong, without a hotel booking and in the middle of the night. The only option to get a few hours of sleep was a (somewhat shady) hourly hotel on the outskirts of the city.
The good news: The next attempt to cross the border was successful. Michael and Flo were allowed to pass at another border crossing. The two had finally made it to Shenzhen.
Border crossing to Shenzhen, first attempt
Done: Finally arrived at the hotel
The well-deserved feast
Michael and Flo with Zhu, the friendliest chauffeur in the world
Border crossing to Shenzhen, first attempt
Done: Finally arrived at the hotel
The well-deserved feast
Michael and Flo with Zhu, the friendliest chauffeur in the world
Shenzhen
When the two finally arrived in Shenzhen, it was a joy to see familiar faces. Flo had been in contact with some of our producer's employees for years, but they had never met in person before.
After checking in at the hotel, Lu, the factory manager, led the small BandWerk delegation to his favorite restaurant: a hot pot restaurant known for its excellent dishes and very generous portions. A warm welcome and a great experience that made up for the exertions of the last few days.
The adapter production: In order for the parts to fit perfectly in the end, a lot of adjustment is required.
In the days that followed, Flo and Michael worked tirelessly to perfect the Apple Watch Ultra adapter in the factory. After several adjustments and improvements, we finally achieved the desired results. The milling machines were precisely adjusted to produce an adapter that met our high quality standards.
Mission accomplished
After finishing his work, Flo returned to Vietnam to enjoy the rest of his well-deserved vacation while Michael continued his journey to Beijing.
At the same time, we celebrated the successful completion of our mission in Munich. Even though it ultimately took much longer than planned, we are happy that our tireless commitment to impeccable quality is finally paying off.
As the saying goes, good things take time. Today we are proud to announce that we use probably the highest quality ultra adapters on the market. And the best part? It's our own design!