Increasing the competitiveness of the XDEEP by developing and implementing a product innovation in the form of a new type of diving device with a closed circuit rebreather.

Description

We manufacture diving equipment that is offered in 67 countries around the world, and the XDEEP brand is a global leader in extreme diving (cave diving, technical diving, rescue). The project will  introduce an innovative closed-circuit breathing diving device with functionalities currently unavailable on the market. It solves two major problems for users of closed-loop devices: the large size and weight (25-35 kg currently), and the closed-loop design which means that the device cannot be configured in any other way than the manufacturer envisioned. Our device weighs a maximum of 12 kg and has a modular design, so that it could be configured for a specific application. It will also be possible to use additional electronic control functions and additional control mechanisms to enhance safety.

Recipients of the innovative product will be entities and individuals involved in diving other than recreational diving. The device will be used in technical diving, exploration diving, commercial diving, Search & Rescue diving and diving in the area of military operations.

The project includes development work culminating in product certification and patent filing, construction of a production hall and purchase of production equipment. We will have a Norwegian project partner, STAVANGER DYKKERSENTER AS, a certified technical centre for global brands of diving equipment. Our cooperation will involve the partner technically optimizing the product for the widest possible commercialization, as well as learning about good business practices in the Norwegian market. The partner recognizes that the new product could be an excellent solution for commercial offshore diving and aquaculture maintenance - so it has huge market potential in Norway. The device can also solve a number of problems related to diving logistics, time constraints and efficiency of diving operations in commercial offshore and aquaculture diving, and the simple and reliable design will ensure low operating costs.

Summary of project results

Diving with closed-circuit rebreathers (CCR) is the most complex and simultaneously the riskiest underwater activity. Despite this complexity, significant advantages over open-circuit diving have led to a dynamic increase in the popularity of this type of diving across nearly all areas of application—from recreational diving, through commercial and scientific diving, to military operations, where CCR systems have essentially replaced other solutions entirely.

Despite many years of development, the CCR devices available today still exhibit the same fundamental flaws as those produced over a decade ago: their heavy weight, which complicates dives in locations requiring air travel, and their high operational difficulty, which contributes to the significant percentage of fatal accidents during CCR dives. The considerable weight of these devices (40–50 kg) also poses challenges for older users, which is particularly important because CCR diving requires substantial experience and is therefore predominantly practiced by individuals aged 40+ or even 55+.

The goal of the project was to increase the accessibility and ease of use of CCR systems by developing and implementing the production of a new closed-circuit breathing apparatus that addresses several key technological issues:

High weight and large dimensions of CCR devices: By reducing the weight and dimensions of the device, the project aimed to make it easier and cheaper to transport by air while also better suited to the needs of an aging society.

• Difficulty of use: By ensuring greater stability and lower susceptibility to buoyancy changes, the project aimed to significantly simplify rebreather operation, which should translate into a reduced number of accidents.
• High amount of waste caused by CNC machining of large parts: By replacing CNC machining with mold forming for the largest components, the project aimed to reduce the negative environmental impact of production.
• High cost of manufacturing: By extensively implementing advanced manufacturing technologies, the project aimed to lower production costs and increase product availability.

As part of the project, the following work areas were completed:

1. Development of the new SIDEWINDER 2 closed-circuit breathing apparatus, based on the patented "cross-flow" scrubber technology, whose concept was implemented and tested as part of the research and development work included in the project.
2. Preparation of documentation necessary for patent applications and submission of patent applications in individual countries, including the EU and the USA.
3. Conducting pre-certification tests and initiating the certification process for the developed device.
4. Development, purchase, and implementation of production machines and tools, such as a complete set of injection molds for manufacturing the "cross-flow" scrubber canister components and a custom-designed "hot plate" welding machine specific to this device.
5. Expansion of the production and warehouse facility by building a new part to provide the space required for the manufacturing of the developed CCR apparatus.

As a result of the project, all planned objectives were achieved, and in many cases, the expected parameters and functionality far exceeded initial assumptions. The developed SIDEWINDER 2 mCCR closed-circuit breathing apparatus offers the following new or significantly improved features compared to competing products:

1. Reduced weight of the device ready for transport compared to units with similar parameters: 12 kg versus 30–40 kg. This facilitates air transport and makes handling easier for middle-aged and older users.
2. Fully modular design, allowing the same device to be used in various equipment configurations (sidemount, backmount, chestmount). This gives users greater flexibility in choosing the configuration best suited for specific dives.
3. Reduced material waste in production by replacing CNC machining with injection molding for the largest components. This has resulted in achieving the targeted reduction in CO₂ emissions and lowering production costs. Consequently, it has been possible to maintain a competitive price for a much more advanced product, thereby increasing its availability.
4. Exceptional CO₂ scrubber performance (absorption time and resistance to overbreathing) while maintaining high ease of use. This allows the device to be used both for simple recreational dives and the most extreme exploration dives. Users will not need to replace equipment as their skills develop, as it offers a functional range suitable for all types of diving.

Summary of bilateral results

Cooperation with the Norwegian partner significantly facilitated gathering information regarding the sales potential of the new product in markets related to offshore construction and the oil industry, as well as understanding customer expectations for the functionality of the new product.Thanks to the collaboration with the Norwegian partner, we were able to establish contacts with individuals and entities from the Norwegian market who provided consulting support in various areas of the project. This enabled us to better tailor the product’s functional features to meet customer expectations. This was particularly crucial for us, as we previously had no knowledge or connections in this sector.Plans for future cooperation include continuing dealership activities, expanding into new market areas, and working together on the planned product development roadmap for the SIDEWINDER 2.