How We (Again) Accelerated the development of the Next Generation of BFR Training Device

Back in 2020, we helped a UK-based sports tech startup bring their first electronic BFR (blood flow restriction) training device to life – reducing their time to market by 3X and helping them overcome major cost and component sourcing challenges during a global crisis.
But the story didn’t end there.
As the device gained success on the market, and became used by professional sports teams (NBA, NHL) and in clinical research all over the world, it was time for the next generation, which will be more compact, modern, and feature rich.
This led to the development of the SUJI Pro version – a smart BFR device designed for ultimate precision in BFR therapy, offering fine-tuned pressure control and real-time feedback.

And once again, the Suji team turned to us to help make it happen.

A New Generation – A New Level of Complexity

Compared to the first generation, the new Suji Pro device required significantly more sophisticated electronics, firmware, and system-level integration to deliver:

  • Precise pressure regulation
  • Over-the-air control and configuration
  • Encrypted BLE communication
  • Live-streamed sensor data
  • Rich sensor fusion from multiple inputs
  • Real-time OLED display output

To achieve this, we have used our existing Motion Sensing Platform and customized it for the needs of the new devices, integrating:

  • Pneumatic pump and valve drivers
  • Gauge pressure sensor
  • OLED display
  • Accelerometer, gyroscope, barometer
  • Memory module
  • Li-PO battery charger and fuel gauge
  • Real-time PID regulation for pressure control

That enabled faster development with the reduced risk, as the development was not starting from scratch but from a solid and reliable base.

From Electronics to Algorithms – Our Contribution

We were responsible for the complete electronics and firmware development, including:

  • Designing the custom electronics
  • Selection and testing of electromechanical components
  • Developing robust firmware in Embedded C
  • Implementing real-time sensor fusion and signal filtering
  • Building a reliable and secure communication protocol with BLE and OTA updates
  • Prototype testing and fine-tuning of control algorithms
  • Performing EMC pre-compliance testing
  • Supporting the certification by helping with documentation and lab testing
  • Assisting with mechanical integration
  • Industrialization and transfer to manufacturing

The result? A smart BFR device, certified as a medical product, that gives athletes and clinicians precise control at the touch of a button – whether directly on the device or remotely via the Suji app.

Why This Matters

What started as a resource-constrained Proof of Concept evolved into a clinically trusted rehabilitation tool, which is designed for accelerated recovery after injury, pain relief, performance enhancement, and reducing the risk of re-injury. And we were proud to support our customers’ journey every step of the way – from initial concept to scaled production.
Whether you’re building a connected fitness product or a clinical-grade medical device, our team is ready to help you bring it to market faster, smarter, and with less risk. Let’s connect!