01 / Challenge
Challenge
A health-tech startup could not settle an argument about strap geometry from renders. Every reviewer had a different opinion about how it would sit on a wrist.
Iterative Design Prototype — 2025
Wearable Sensor Housing
Eleven revisions of a wrist-worn enclosure printed over three weeks, each one worn for a day before the next was cut.
PETGFDMProduct Design
Preparing 3D view
Loading geometry and materials.
- Project
- Wearable Sensor Housing
- Material
- PETG
- Technology
- FDM
- Print Time
- 4 hours
- Layer Height
- 0.15 mm
- Weight
- 22 g
- Dimensions
- 52 x 38 x 16 mm
- Industry
- Product Design
02 / Design
Design
We set up a parametric model with strap angle, shell curvature and lug spacing as driven variables, so a revision was a number change rather than a remodel.
03 / Printing Process
Printing Process
Each revision printed in under four hours in PETG at 0.15 mm, with a TPU strap printed alongside. Revisions were worn for a full day before feedback was collected.
04 / Final Result
Final Result
Revision eleven went to tooling. The team estimated the print-first loop saved roughly six weeks against their original CNC prototype plan.
Gallery
Through the build
Four moments from the job, in the order they happened.
- 01
Revisions one through eleven - 02
TPU strap and shell together - 03
Internal PCB fit check - 04
Final revision, worn
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Wearable Sensor Housing
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