The client approached us looking for a redesign of the outer housing of their existing product, looking at making it a sleeker, more contemporary looking piece, improving the durability and waterproofness and also improving the functionality of the activation button. They also wanted us to find a solution for lowering their per unit price and consolidating labour in assembly with a new manufacturer.
We considered different manufacturing processes and settled on ultrasonic welding as being the best option for sealing the unit post assembly, to help with durability and waterproofing. Giving the new housing more considered lines, we took out unnecessary material wastage and interior space, making the product thinner and as a result cheaper to produce. In addition, we minimized the wall thicknesses and reconfigured the interior layout of PCB and battery to make the activation clicker more accessible and responsive.