IIF contacted Porticos to redesign their triathlete tracking device. Their goal was a redesign that would use the same electronics and back cover to minimize costs, while giving the device a more rugged appearance, fitting its use.
Design Challenges and Solutions
It was difficult for users to tell whether they had pushed a button, the indicator lights were unclear, and accidental button presses were common.
Porticos provided options for the exterior appearance and created concepts to improve function, all while requiring no changes to the electronics or back cover.
- Porticos designed a button geometry that would give a clear, tactile feel to the user
- Working around existing electronic components, engineers created custom light pipes to bring each indicator light to its associated button, integrating them into the icons
- Without increasing the device thickness, the buttons were recessed to prevent accidental presses
- The molded-in logo and button icons clearly mark the product and are durable in use
- To check button feel and light pipe operation, Porticos used the 3D design files to build a working prototype of the new design
- Excellent tactile feedback was confirmed, and the indicator lights could be seen clearly in bright daylight
Tooling, Assembly Support & Testing
- Engineers identified tooling options, and worked with toolmakers to get high-quality production plastic parts
- Porticos provided assembly instructions for the contract manufacturer and helped them work through build issues
- Porticos performed verification testing on the device to determine water and shock
- Injection Molding
- Two shot molding
- Ergonomic design
- Electronics packaging
- Water intrusion
- Impact resistance
- Wearable electronics
- Rugged electronics