For the final assignment in my Product Development and Manufacturing course, I led the enclosure design for a wearable heart rate sensor. The brief required the housing to be production-ready, waterproof, and pleasant to use during athletic activity. Meeting those goals meant balancing aesthetics, manufacturing constraints, and an ambitious electronics package.
Design for Manufacturing from Day One
I modelled all components in Fusion 360, incorporating draft angles, parting lines, and realistic tolerances for injection molding. Each mating surface was dimensioned so the design could shift from 3D-printed proof-of-concept to mass production without rework.
Making Waterproof Feel Invisible
- Engineered an O-ring channel that maintains compression while avoiding interference with internal electronics.
- Selected a translucent material region that allows the status LEDs to shine through while protecting them from moisture.
- Integrated a capacitive touch button that remains responsive through the sealed exterior, eliminating mechanical openings.
Testing & Iteration
Rapid prototypes focused on validating assembly order, gasket performance, and button responsiveness. I built a simple water ingress test and used dye penetrant checks to confirm the sealing strategy. Each iteration refined screw boss placement and cable routing to reduce build time.
Skills Demonstrated
- Mechanical design and CAD for manufacturability.
- Waterproofing strategies including material selection and seal design.
- Design documentation that supports both low-volume and scaled manufacturing.