Helping shape research into reality

When researchers develop promising concepts, translating those ideas into real-world products is often the biggest challenge. That’s where collaboration with skilled external partners can make all the difference.

Vital Spark Creative, based in Cornwall, has worked with several University of Exeter academics to help bring early-stage ideas to life. A design and engineering consultancy, they specialise in developing concepts into fully realised, testable products; from early sketches through to 3D CAD modelling, prototyping, and small-batch manufacture. Their experience spans a wide range of sectors – from specialist engineering and biotech to consumer products – but recent projects with the University have focused on sustainability, biodiversity, and clean energy.

One example is VespAI, a project from the Environment and Sustainability Institute aimed at developing a field-deployable device for detecting Asian hornets, a species that poses a growing threat to pollinators in the UK. The system uses an overhead camera and scent attractant to lure insects to a landing pad. An AI model then identifies whether the insect is an Asian hornet, triggering a local alert. The aim is to provide an early warning system to support monitoring and reduce unnecessary bycatch of native insects.

When the team first approached Vital Spark, the prototype was still in its early stages and was built with improvised materials. Working together, they developed a more robust 3D-printed unit with a camera mount, rain shield, and a refillable reservoir for the attractant. The design proved robust and worked well in field trials in Jersey and Kent.

Dr Peter Kennedy, who conceptualised the system, said, “Vital Spark took the time to listen to what we were trying to achieve and designed a unit that answered the full brief, keeping the project on track. Our project partners were impressed with the quality of the hardware developed.”

“The fact that the company is also local to the Penryn campus meant it was easy to meet in person. This made addressing some of the practical challenges of the project much easier.”

A few years ago, Vital Spark also supported the University of Exeter’s commercialisation project, Build Solar, by helping to visualise Solar Squared, an innovative solar glass block developed by Dr. Hasan Baig and Professor Tapas K. Mallick. The blocks incorporate solar cells into architectural glass, enabling buildings to generate power without compromising aesthetics or natural light. At a time when the project needed to attract partners and industry interest, the high-quality visuals produced by Vital Spark were instrumental in showing what the technology could look like in practice.

“We enjoy working on projects where there’s a clear purpose and a strong idea, we help shape it into something tangible,” said Chris Booker, Director at Vital Spark Creative.

For researchers, especially those without previous experience in product development, the right partner can simplify the journey from concept to prototype. It’s also a reminder of the critical role that regional businesses play in enabling research impact by offering technical skills, fresh perspectives, and hands-on collaboration that accelerates the path to application.

Chris said, “There are some very clever people doing some really interesting things at the University of Exeter, and if we can be involved with that and package it into something that’s a little bit more presentable, it’s a win-win.”

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