With the success of the G7 gas sensor technology, Blackline Safety seized the opportunity to expand its product line. This led to the creation of the EXO, a product similar to the G7 but designed for three months of continuous use to create an on-site monitoring network over a designated area. The product needed to be transportable, easily deployable, and able to withstand outdoor environmental challenges. This product will become invaluable for workers and first responders in areas exposed to potential hazardous gases.

A product like the EXO needs to maintain its integrity under all conditions. Given its use in dangerous environments, it must be intrinsically safe and certified accordingly. Multiple drop test scenarios were necessary, often exceeding military standards like MIL-STD-810. Drop testing is often used to validate that a product can still function after a fall. This doesn't mean the product won't sustain damage; it means that even if it does, it will continue to operate effectively and won't pose a risk to the user.

The EXO consists of over 60 parts, including 15 seals to prevent water or gas infiltration. Many components are essential for user interaction, such as keypads, a screen, and transparent parts for alarm visibility. The bumpers are reinforced with metallic structures for increased durability. Symmetrical parts, which are necessary, add complexity to the assembly process and require significant tooling investment. A less demanding product in terms of safety and sealing standards would not need as many parts.

Material selection posed a challenge, as the materials must not become hazardous. In high-volatility gas environments, static electricity is a major concern, so all plastics in the EXO had to be anti-static. Finding materials that met both mechanical and anti-static requirements was challenging, but a reliable partner now supplies these materials.

The EXO provides visual and sound alarms to alert workers. Ensuring the product is watertight while allowing sound to escape was a challenge. A custom horn design was developed to enhance sound propagation without increasing power consumption, maintaining the intrinsically safe requirement. The enclosure was designed with a gutter system to prevent water ingress, even under high-pressure hose conditions, ensuring the buzzer remains effective and safe.

As demonstrated in the video, the EXO is built to last and withstand harsh environments. Initially designed to meet IP66 standards, most parts were created with IP67 standards in mind. The aluminum body contributes to the product's durability, providing stability against temperature changes. Outdoor factors like water, snow, ice, wind, direct sunlight, heat, UV, and projectile impacts can all affect the product's performance over time. Customers expect long-lasting and reliable performance from the EXO, which is why it is designed to such high standards.