Michael here. This is a BIG week for Bía!

We've shipped masks to all 500 Beta customers. In fact, some of them have already started using Bía.

Previously, you provided feedback that you wanted to know what was happening behind the scenes. Today, I want to zoom out and walk you through the production schedule in full detail.

Over the next two weeks we'll be laser focused on providing a great experience, fixing bugs, and making sure the next batch of Bía Sleep Masks work perfectly for the next batch of customers.

Today I want to talk to you about our production schedule.

Production Schedule

Now that we’ve completed a full production run from start to finish, we have a clear picture of how long each step takes.

Bía is not a simple product. It is made from hundreds of parts across electronics, sensors, batteries, audio, fabric, foam, silicone, and packaging.

Each part needs to arrive on time, pass inspection, fit into the build, and work together through the night.

Here’s what the full path looks like:

1. Sourcing

Every Bía Sleep Masks starts with ordering hundreds of parts from different suppliers around the world. Some parts are quick to source. Others, like our memory chips, take 6 months to arrive after we place the order.

The good news: sourcing is complete for all current orders

2. PCB Production.

The PCB (Printed Circuit Board) is the panel that holds and connects Bía’s chips, sensors, and other electronic parts. It is made through a precise, multi-step process that forms fine copper pathways across several thin layers, then bonds and connects them into one working board.

Timing: 4 weeks

3. PCB Assembly.

Once the boards are made, the electrical components are added.

This is where machines place tiny parts onto the board, solder them in place, and run the board through inspection and testing. Some parts need extra care before they can be assembled. Our fNIRS sensor, for example, takes five days of preparation before it can be placed onto the board.

Timing: 3 weeks

4. Final Assembly

The electronics are placed into a silicone housing, connected to the batteries, bone-conduction audio, and buttons, then sealed for protection. That assembled silicone housing is then inserted into the soft mask.

Timing: 1 week

5. Quality Control.

Each mask is thoroughly tested and put through a 10-hour trial run to make sure everything is connected and working the way it should.

Timing: 1 week

6. Inbound Shipping.

Once the masks are complete, they are packed onto pallets, moved to the airport, flown across the world, cleared through customs, trucked to the warehouse, and unloaded.

Timing: 1 week

7. Delivery.

Once your Bía reaches the warehouse, the team scans your order, picks your items, packs them into our custom Bía boxes, and sends everything to your doorstep.

Timing: 1 week

Timeline Adjustments

Now that Beta has shipped and we have real production data, we’re starting a new production run every month.

• 1,000 masks started production September 1st.
• 2,000 masks starting in October
• 3,000 masks starting in November
• 4,000 masks starting in December
• Up to 5,000 masks starting each month after

If your account originally showed a September delivery window, you’re part of the current production run. Based on what we know today, we expect to deliver Bía to you in November.

You can now log into your account to see which stage of production your order is in. We'll update your account every week when new production information becomes available. 

This gives you visibility from now until Bía arrives at your door.

We’re excited to finally be moving from guesswork into repeatable production.

More soon.