UV Dry Box

Keep your hearing aid sanitised

Compact, lightweight, and easy to use, Hansaton’s UV Dry Box uses ultraviolet light to sanitise and extract moisture from hearing aids. Simply store your hearing aid in your dry box overnight or when it is not in use and let it work its magic.

Client: Hansaton
Website: hansaton.de

Pilotfish helped Hansaton to go from concept to production, taking care of the entire development process. 

We began with the initial product design and continued through the proof of concept, engineering, tool making and testing as well as the final manufacturing and assembly.

Additionally, Pilotfish was responsible for the laboratory tests and made sure the product matched the CE and FCC certification standards. Due to the design of the UV Dry Box, the production is very flexible and we were able to customize the product with low minimum order quantities. Plus, because of our smart tooling, two different versions of the product can be produced without any additional investment.

Products manufactured
Years working together
Pilotfish did: 

Product DNA

The purpose of the DNA phase is to understand the user, market, and technology as well as clearly outline the product definition document (PD). In addition, we conduct qualitative user research through user observations and interviews and then develop personas and user cases. Together, the PD and user-based research result in the initial product concept ideas.

Proof of Concept

In the POC phase, we develop the working principles and test them. All critical and unknown aspects of the product have to be understood and problems must be solved before moving onto the next phase.

ID & UX Design

During the ID phase, we create the product’s appearance and user interaction. We not only make sure that the product is designed to be ergonomically friendly and visually appealing but also keep the production feasibility and cost needs in mind. By working hand in hand with engineers and production managers, we design the product to minimize the risks and costs that may occur during the production phase.


Our team of engineers designs the encasement and all details for production, including draft angles, screw bosses and ribs for assembly. The engineering work is tested with working prototypes and the final deliverables are 3D files and supporting documents ready to start tooling. Pilotfish can also manage the development of the electronics with the support of our team in Taiwan.

Tooling & Production

Pilotfish oversees all tool design and the quality control of the tool production. We diligently work with trial samples until we reach the golden sample, or in other words, the perfect set of finished parts. During the pilot run, small batches of the product are made for end users to test as well as for marketing and promotional purposes and CE/FCC certification. After the pilot run, Pilotfish manages the production of the finished, ready to sell product.

Final Assembly

Designing parts for efficient product assembly is a crucial consideration during hardware development. We ensure that the product is designed with the minimum number of steps on the assembly line in order to avoid tremendous costs and production delays. Although Pilotfish can design the quality control (QC) process and all necessary test jigs, we keep the process transparent. If desired, the client can always do their own QC or determine how many items we should test. We can test every item that comes off the production line or sample only a specific percentage of the production batch.


The product is only finished when it’s packaged and ready to be shipped to the final customer. We deliver a fully finished product, including the packaging design and the product manual. We also source the necessary accessories (for example, a suitable charger or cables) and take care of export packaging for sea and air freight.

Behind the Scenes

While working together for 18 years, we have developed countless versions of this product, exploring options for production optimisation and increasing the ease of use. Here is a small preview of our process.