Over the past four weeks, the enclosure for our proof-of-concept model has undergone an iterative design and development process. The baseline architecture consists of a rectangular geometry featuring four mounting holes for lid fixation. To ensure long-term structural durability and enable successive opening and closing cycles without material degradation, brass threaded inserts (heat-set inserts) were integrated into the design.
The initial 3D model was developed in collaboration with a team member from eNGN Technologies, establishing a solid foundation for the subsequent evolution of the prototype. Following this phase, with the logistical support of iStartLab, two additional iterations were manufactured using 3D printing techniques. Each prototyping cycle focused on optimizing four essential pillars: ergonomics, functionality, practicality, and resistance (both mechanical and thermal), while consistently prioritizing the minimization of the structure’s overall weight to enhance portability.
The current prototype is manufactured from PETG, a polymer that offers an excellent balance between rigidity, flexibility, and impact resistance, ensuring reliable operation even under adverse conditions.
Design and Ergonomic Optimizations:
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Ergonomic Attachment: The system is secured to the user’s body using two adjustable elastic straps, anchored to two lateral arms integrated into the structure.
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User Comfort: The enclosure surface in direct contact with the skin was slightly curved/rounded to mitigate pressure points and prevent discomfort during prolonged use.
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Structural Reinforcement of the Arms: The lateral arms were redesigned by applying internal fillets to reduce friction and prevent premature wear of the elastic straps. Additionally, their junctions with the main walls of the enclosure were geometrically reinforced to withstand the mechanical stress resulting from tensioning the straps.
As future work, a fourth and final iteration is planned. This final version will feature a aesthetic and functional redesign of the lid, along with minor additional geometric adjustments aimed at maximizing end-user convenience.