Seamless integration of the device into the users' daily activities is essential for creating a satisfactory user experience to prevent of product abandonment. Hence, I aimed to unlock the device's compatibility with a diverse ecosystem of tools by considering standard measurements for wearable devices and furniture while ideating the device's implementation methods.

The design of the PCBA enclosure was mainly driven by the mounting mechanism of the device in its operating environment. I worked closely with the team's industrial designer to ideate multiple implementation concepts in the form of wearable devices, clothing attachments, and furniture accessories.

At the end of our discussion, we had 8 design concepts. To identify the optimal solution, I created a ranking chart that compared the effectiveness of each concept based on the degree to which they fulfilled each requirement for a more quantifiable analysis.

To support the electrical functions of the device, I sourced the hardware components for both the device and wireless charging dock, which were then used to draft the PCBA layout.

I first created a simple model for baseline testing to uncover both successful and ineffective features to inform subsequent design iterations.

After 3D printing and assembling the prototype, I discovered two problems to target for the next design concept:

After the first concept, the model was modified multiple times to reduce the size and implement the ability to attach mounting accessories. The model eventually deviated from its original rectangular shape to a dome-like form to deliver a more organic and natural feel, enabling the product to blend more seamlessly into the surrounding environment

Upon 3D-printing the third iteration, I discovered that the top and bottom housings could not be assembled due to an interference in the parts illustrated below. This meant that at the current stage, the product failed to provide full protection around the PCBA.

With the misalignment of the two points of first contact in iteration 3, the cantilever beam of the snap joint would need to bend an excess distance of “d". Since the print filament was made of polylactic acid (PLA), a rigid material with a minimal deflection range, the slanted wall caused the model to fail.

Throughout the course of the project, I evaluated each design iteration according to a set of goals I strived to meet in thedesign of my prototypes. This practice enabled me to assess the growth in my mechanical design skills based on the qualityof the prototypes created.