Cygnus SN-Pro: The world’s first fully EN 54 certified 100% wireless fire alarm system
Cygnus, a leading UK innovator in wireless fire detection technology, approached us with a bold vision. To create the first fully wireless, EN 54 certified, IP65 rated fire alarm system. The goal was to eliminate the long-standing constraints of hybrid systems and simplify installation, servicing and deployment. All without compromising safety or design integrity.
By combining user-centred design, advanced engineering and our deep understanding of manufacturing, we helped bring Cygnus SN-Proto market. And create a pioneering product that’s redefining the global fire safety industry.
Challenges in the fire alarm industry
The fire alarm industry face fundamental limitations that cost installers’ time, money and safety. The brief was about rethinking how wireless fire alarm systems are deployed and maintained, alongside building a better product. We worked closely with Cygnus to tackle five challenges:
- Move beyond hybrid limitations: Deliver a completely wireless system supporting up to 2,555 devices via mesh networking. Competitors were currently limited to 32-device hybrid systems.
- Solve installation pain points: Address complex wiring, time-consuming installations and mounting challenges across different wall types.
- Improve maintenance safety: With engineers frequently required to use ladders to service systems, we set out to design for ground-level access.
- Reduce component complexity: We aimed to minimise parts and reduce manufacturing costs by creating one modular enclosure for multiple device variants.
- Maintain design coherence: Ensure the SmartNet-Pro aligned visually and functionally with the existing Cygnus product family whilst suiting a modern office aesthetic.
Our design approach
Multi-user journey mapping
Establishing a universal mounting solution
Recognising that commercial buildings vary in layout, size and materials widely, we designed a clever mounting system that works across brick, cavity and plasterboard walls. The housing accommodates various fixing methods with minimal screws and can even be recessed into cavity walls for a smooth finish.
Breakthrough servicing innovation
We engineered a bespoke pivoting hinge and locking mechanism allowing full access from ground level using a custom removal tool. The hinge opens at precisely calibrated angles for tool-free panel removal during servicing – eliminating working at height risks.
Consolidated components for smarter modularity
Where form meets functional design
We developed a sleek IP65-rated enclosure that resists dust, vibration or moisture. The elegant system can be surface-mounted or recessed to blend into prestigious reception areas while maintaining full EN 54 certification recommended for construction sites. No more unsightly steel boxes.
Manufacturing partnership and cost optimisation
We collaborated early in the prototyping stage with local manufacturing partners to streamline assembly, reduce SKUs and smooth scalability. Our in-house 3D printing capabilities allowed for rapid prototyping and refinement throughout the development process.
Key outcomes and the commercial impact
Simplified installation
Installation time: Reduced a typical hardware installation time from one week to one day. A huge improvement benefit in an industry facing a major labour shortage and increasing material costs.
Wireless capability: Up to 2,555 devices across five panels.
Universal mounting: Works across all wall types with simplified fixing methods.
Servicing and safety transformation
Health and safety: No ladders required for maintenance. A bespoke pivoting hinge and custom removal tool enable full ground-level access for servicing.
Faster servicing: Reduced site downtime and increased system uptime and reliability.
Touch interface: Easy to use screen removes the need for mechanical changes during updates.
Remote configuration: Cygnus Configuration Software Tool and Portable Programming Unit (PPU) enable wireless device programming and firmware updates on site, reducing engineering time for commissioning and ongoing maintenance.
Business benefits
Lower costs: Fewer components and parts means a decreased Bill of Materials (BOM) which streamlines production and assembly.
Scalable design: One enclosure fits multiple devices improving flexibility.
Market disruption: Creating the first fully wireless and globally EN 54 certified fire alarm system is a clear differentiator.
Sales impact: Cygnus SN-Pro has helped Cygnus gain market share and secure a substantial uplift in sales and visibility.
Technical innovation highlights
A world-first achievement: SmartNet-Pro is the first EN 54 certified 100% wireless fire alarm system globally.
Scalability: Supports 511 devices per panel and is expandable to over 2,500 across five panels. This is 78x more than the industry-standard 32-device hybrid limitation.
Environmental resilience: Its IP65 rating handles construction site challenges including dust, vibration, temperature extremes and electromagnetic interference.
Future-ready design: Modular architecture allows for future software updates and modular hardware additions without system replacement.
Our reflection on the project
Cygnus SN-Pro represents what’s possible when bold ambition meets user-first design thinking. From first sketches to final assembly, our team immersed themselves in the world of fire detection – uncovering insights, solving technical barriers and optimising every touchpoint from installation to servicing.
This project isn’t just about making a new product. It’s about reshaping an industry standard. We’re proud to have supported Cygnus in launching a system that combines world-first functionality, practical elegance and production-ready performance.
