Wearable Design and Production
Concussion sensor and postural sway measurement device for contact sport athletes
"With the Protxx wearable sensor and data platform, real-time athlete biometrics that enable early intervention, safer play, reduced injury incidence and severity, improved recovery outcomes, and higher levels of performance are now available during every game and practice."
Smaller than an earbud, with the power to help billions of athletes and neuro patients worldwide. I worked with PROTXX, their electrical engineering partners, and their contract manufacturing partners to take their proof of concept sensor array to a manufacturable, self-contained device. Waterproof and light as a feather, these sweet devices stick to an athlete's mastoid using strong but skin-safe adhesive to measure their head movement.
I contributed by redesigning the proof of concept from a flexible, battery-replaceable design to a compact design with an integral battery. The design is comprised of several completely custom mechanical and electrical components, and I specified a lot of them. I worked with the battery manufacturer to create battery terminals that were tolerant of assembly variation by implementing a unique but low-cost shape that allowed one terminal to stretch and flex. I kept process in mind for all of my design variations and specifications. I designed several versions of the final housing for different connection methods, and supported tool bring up. Once molded components were ready, I made a lot of the first prototypes in our shop at Swope Design Solutions. I created the design history file for the product and was directly responsible for all specifications. I supported assembly line bring-up and helped troubleshoot issues. Everything was pretty smooth and the product design remains largely the same today. I even had a special treat of working with a classmate of mine from college, who had been hired separately to design the charging case. This was one of my favorite projects to date.
I contributed by redesigning the proof of concept from a flexible, battery-replaceable design to a compact design with an integral battery. The design is comprised of several completely custom mechanical and electrical components, and I specified a lot of them. I worked with the battery manufacturer to create battery terminals that were tolerant of assembly variation by implementing a unique but low-cost shape that allowed one terminal to stretch and flex. I kept process in mind for all of my design variations and specifications. I designed several versions of the final housing for different connection methods, and supported tool bring up. Once molded components were ready, I made a lot of the first prototypes in our shop at Swope Design Solutions. I created the design history file for the product and was directly responsible for all specifications. I supported assembly line bring-up and helped troubleshoot issues. Everything was pretty smooth and the product design remains largely the same today. I even had a special treat of working with a classmate of mine from college, who had been hired separately to design the charging case. This was one of my favorite projects to date.
This is actually a solid, fully colored, 3D printed model I made before we had production tooling complete. How cool is that?!