Hardware Cost Breakdown
Executive Summary
The hardware infrastructure requires an estimated $110,000-$140,000 investment for a complete 40-station system supporting 80 athletes simultaneously using industrial-grade camera sensors. The development configuration using NVIDIA Jetson Orin NX modules costs $110,000 and is suitable for most events, while the production configuration with RTX 4060-based edge servers costs $140,000 and provides enhanced performance for championship events. These preliminary estimates assume the custom sensor approach and will evolve as we refine specifications through testing and vendor negotiations.
Kit-Based Deployment Model
Competition Kit Architecture. Each kit supports 8 wall ball stations (16 athletes) and operates as an independent unit that can be shipped between venues in ruggedized cases. This modular approach allows HYROX to deploy exactly the right amount of equipment for each event size, from regional competitions needing just one kit to world championships requiring five or more. The self-contained design ensures that a failure in one kit doesn't affect others, providing natural redundancy for critical competitions.
Cost Optimization Strategy. These estimates represent our target budget ceiling based on current market analysis of industrial vision components. We will work to reduce costs through volume purchasing agreements, alternative component sourcing, and design optimizations discovered during the alpha phase. The goal is to deliver professional-grade reliability while keeping the bill of materials at or below these preliminary estimates.
Preliminary Cost Estimates (Industrial Sensor Approach)
These estimates assume the custom industrial sensor approach using professional-grade cameras rather than consumer mobile devices. The costs are based on current market research and will be refined through vendor negotiations and testing. All prices are subject to change as we optimize the design and identify volume purchasing opportunities.
Per Kit Breakdown (8 Stations)
Development Configuration (Jetson-based)
| Component Category | Estimated Cost | Description |
|---|---|---|
| Vision System | $13,000 | 16× cameras and lenses |
| Edge Computing | $3,650 | 2× Jetson Orin NX units with networking |
| Target Sensor Integration | $360 | Interfaces for existing acoustic sensors |
| Ruggedized Transport Cases | $1,200 | Protective cases for shipping between venues |
| Infrastructure | $590 | ChArUco calibration and protection equipment |
| Misc (Mounting, Cables, etc) | $1,600 | Hardware, cabling, accessories |
| Development Kit Total | $20,400 | Suitable for most events and regional competitions |
Production Configuration (Edge Server-based)
| Component Category | Estimated Cost | Description |
|---|---|---|
| Vision System | $13,000 | 16× cameras and lenses |
| Edge Computing | $9,250 | 1× RTX 4060 server (handles 16-32 stations) |
| Target Sensor Integration | $360 | Interfaces for existing acoustic sensors |
| Ruggedized Transport Cases | $1,600 | Enhanced cases for server equipment |
| Infrastructure | $590 | ChArUco calibration and protection equipment |
| Misc (Mounting, Cables, etc) | $3,200 | Enhanced networking, cooling, redundancy |
| Production Kit Total | $28,000 | Enhanced performance for championship events |
Vision System Details. The vision system estimate includes industrial cameras based on the Sony IMX273 sensor, such as the Basler ace series, which provides global shutter capture at 1440×1080 resolution. These cameras eliminate the motion artifacts that would occur with rolling shutter sensors during rapid athlete movements. The estimate also includes C-mount lenses with approximately 70° field of view for optimal court coverage.
Edge Computing Architecture. Each kit requires two edge computing units to maintain sub-200ms processing latency across all stations. Current estimates assume NVIDIA RTX 4060-based systems with TensorRT optimization capabilities. Alternative configurations using NVIDIA Jetson AGX Orin or Intel-based systems with discrete GPUs will be evaluated during the alpha phase to potentially reduce costs while maintaining performance requirements.
Target Sensor Integration. HYROX already has acoustic sensors installed at their wall ball targets, eliminating approximately $800 per kit from our original estimates. We only need to provide interface boards such as ESP32-PoE modules to connect these existing target sensors to our vision processing pipeline. This integration approach reduces both cost and complexity while leveraging HYROX's proven sensor technology for accurate hit detection.
Ruggedized Transport Cases. Each kit requires professional-grade transport cases such as Pelican cases to protect sensitive equipment during shipping between venues. These cases must withstand rough handling, provide shock absorption for cameras and computing equipment, and include custom foam inserts for secure component placement. The estimated $1,200 per kit covers multiple cases with wheels and TSA-approved locks for international shipping.
Full System Deployment
Standard Competition Configuration. A full 40-station deployment supporting 80 athletes requires five competition kits plus contingency equipment. The total hardware infrastructure investment ranges from $110,000 (development configuration) to $140,000 (production configuration), depending on compute platform selection:
- Development Configuration: 5 kits × $20,400 = $102,000 + contingency = $110,000
- Production Configuration: 5 kits × $28,000 = $140,000 (includes contingency)
These figures represent our budget range and will be refined as we negotiate with suppliers and optimize the design through testing.
Deployment Scaling
| Event Type | Athletes | Kits | Development Config | Production Config |
|---|---|---|---|---|
| Regional Competition | 16 | 1 | $20,400 | $28,000 |
| Standard Event | 32 | 2 | $40,800 | $56,000 |
| Major Competition | 48 | 3 | $61,200 | $84,000 |
| Championship | 64 | 4 | $81,600 | $112,000 |
| World Finals | 80+ | 5+ | $102,000+ | $140,000+ |
Flexible Deployment Model. The kit-based architecture allows HYROX to match equipment deployment to event size, shipping only the necessary kits to each venue. This approach dramatically reduces per-event costs compared to fixed installations while maintaining consistent judging quality across all competition levels.
Investment Analysis
Initial Estimates vs Refined Budget. Our original proposal estimated $25,000 per venue for hardware, which assumed simpler equipment and fixed installations. The revised analysis recognizes the need for professional-grade industrial cameras and edge computing to achieve 95% accuracy in challenging competition environments. While the initial investment of $100,000 appears higher, the kit-based model delivers superior economics through venue reusability.
Return on Investment Projection. The kit model transforms the economics of automated judging by amortizing the hardware investment across multiple events. With 20 competitions per year, the effective per-event cost drops to $5,000 in year one, compared to $25,000 for venue-specific installations. By year two, with only maintenance costs of approximately $10,000 annually, the per-event cost falls to just $500. Over a five-year period, the total cost of ownership reaches approximately $140,000 for 100 events, delivering a per-event cost of $1,400.
Competitive Advantage. This investment enables HYROX to offer consistent, objective judging across all venues without the variable costs and logistics of venue-specific installations. The portable kit model also allows rapid deployment to new markets and special events without additional capital investment.
Technology Selection Rationale
Camera Sensor Choice. The Sony IMX273 sensor represents the optimal balance between performance and cost for this application. Its global shutter technology completely eliminates the motion artifacts that would plague rolling shutter sensors during rapid athlete movements. At 1440×1080 resolution and 73 frames per second, it provides sufficient detail for accurate pose estimation while keeping data rates manageable. Current market pricing for cameras like the Basler ace series ranges from $600-800, making them cost-effective compared to higher-resolution alternatives that would provide minimal accuracy improvements.
Edge Computing Platform. The NVIDIA RTX 4060 graphics processor delivers the AI performance necessary for real-time inference at each kit. With 240 Tensor TOPS and full TensorRT optimization support, it can process multiple camera streams simultaneously while maintaining sub-200ms latency. The 115W power consumption fits within portable system designs, and at approximately $500 per GPU, it costs significantly less than data center cards while providing comparable inference performance for our specific models.
Network Architecture. Power over Ethernet Plus (PoE+) technology simplifies deployment by combining power and data over a single cable per camera. This reduces setup time, eliminates multiple power supplies, and improves reliability by minimizing connection points. The GigE Vision standard ensures compatibility across camera manufacturers while providing sufficient bandwidth for uncompressed video transmission.
Procurement and Cost Optimization
Volume Purchasing Strategy. Ordering components in quantities of 80+ cameras and 10+ computing systems unlocks significant volume discounts. Camera manufacturers typically offer 15-20% reductions for orders of this scale, while computing hardware can see 10-15% discounts. Extended warranty packages become more cost-effective at volume, and maintaining a shared spare parts pool across all kits reduces per-unit contingency costs.
Alternative Component Evaluation. During the alpha phase, we will evaluate alternative components that could reduce costs while maintaining performance requirements. This includes testing FLIR Blackfly cameras as an alternative to Basler, evaluating AMD Radeon graphics cards for inference workloads, and exploring integrated solutions like NVIDIA Jetson AGX Orin that combine CPU and GPU in a single module. Each alternative will be benchmarked against our 95% accuracy requirement and sub-200ms latency target.
Mobile Phone Alternative Comparison
Analysis Results from Comprehensive Evaluation. Our detailed mobile phone alternative analysis reveals that while modern smartphones offer sophisticated capabilities, they introduce unacceptable technical limitations and operational complexities for production deployment. The Pugh matrix evaluation shows industrial cameras scoring +191 compared to -158 for mobile phones, a decisive 349-point advantage across critical evaluation criteria.
Cost Reality of Mobile Deployment. Despite initial assumptions of cost savings, our analysis demonstrates that a 40-station iPhone deployment would require 80 devices at approximately $1,000 each, totaling $80,000 in phone costs alone. When factoring in mounting hardware, continuous power supplies, potential cooling solutions, and device management overhead, the 5-year total cost of ownership reaches $293,250 for phones compared to $119,750 for industrial cameras—making phones 2.5× more expensive over their operational lifetime.
Technical Limitations Drive Decision. The mobile phone analysis identified critical technical issues including rolling shutter artifacts causing up to 10% error in joint angle measurements, thermal throttling reducing performance by 40% after 10-15 minutes, and synchronization challenges with 1-5ms timing errors that compromise 3D reconstruction accuracy. These limitations directly impact the ability to achieve our 95% true positive rate requirement for automated judging.
Industrial Cameras Provide Required Performance. Based on the comprehensive evaluation, industrial cameras with global shutter technology, hardware triggering, and deterministic performance characteristics are the only viable solution for HYROX's production deployment. The GigE Vision interface with PoE+ support provides the reliability, synchronization precision, and sustained performance necessary for consistent judging across hundreds of annual competitions.
Maintenance and Support
Annual Operating Budget. Maintaining the system requires approximately $10,000 annually, representing 10% of the initial hardware investment. This covers replacement components for normal wear and tear, calibration equipment updates, shipping case maintenance, and vendor support contracts. The relatively low maintenance cost reflects the industrial-grade quality of the selected components and their proven reliability in similar deployment scenarios.
Component Lifecycle Planning. Industrial cameras typically operate reliably for 5-7 years in competition environments, while edge computing hardware follows a 3-4 year refresh cycle driven by AI model improvements rather than hardware failure. Network equipment and mounting hardware should last 5-10 years with minimal maintenance. This staggered replacement schedule allows HYROX to spread upgrade costs over time rather than facing complete system replacement.
Technology Evolution Path. The modular architecture accommodates incremental improvements as technology advances. Year two may see GPU upgrades to support enhanced AI models, while year three could introduce higher resolution cameras if accuracy improvements justify the investment. By year five, a comprehensive system evaluation will determine whether emerging technologies warrant a platform refresh or if incremental upgrades remain the optimal strategy.
Budget Target Summary
These preliminary estimates establish a $110,000-$140,000 budget range for the complete 40-station hardware system, with configuration selection based on event requirements:
- Development Configuration ($110,000): Jetson Orin NX-based system suitable for most events
- Production Configuration ($140,000): RTX 4060 server-based system for championship events
Both configurations include all cameras, networking, ruggedized transport cases, and integration components necessary to achieve 95% judging accuracy. While these estimates are based on current market research and technical requirements, they will be refined through:
- Vendor negotiations and volume purchasing agreements
- Component testing and optimization during the alpha phase
- Alternative technology evaluation and benchmarking
- Design refinements that reduce complexity and cost
Our commitment is to deliver professional-grade automated judging infrastructure at or below these target costs, ensuring HYROX receives maximum value from their technology investment. The kit-based deployment model transforms a significant capital expense into a flexible asset that can support hundreds of competitions over its operational lifetime, fundamentally changing the economics of consistent, objective athletic judging.