Digital Lumens - Sensor product
Cross-section view of sensor product
Next Generation Sensor Product
During my time at Digital Lumens, I worked on a next generation sensor product. It was an immense learning experience concept to production product development.
Used Master Modeling in SolidWorks to manage complex electro-mechanical assembly
Prototyped plastics design using 3D printing for rapid iterations
Designed molded plastics, sheet metal parts and wire formed parts
Integrated Digital Lumen's Industrial Design aesthetic from past product lines to create a seamless addition
Conducted ESD, thermal and other electrical testing for UL, cUL, and CE compliant systems; product rated to IP65 and large thermal range
Communicated with off-shore Contract Manufacturer in order to incorporate DFM feedback and manage timelines
Mechanical Deep dive
Below I show the evolution of a really unique plastic part I developed. Since there isn’t much room within the enclosure, there needed to be a clear wire management solution. Wago clips were standard for splicing into connections, and I tested out a snap fit mounting scheme adjacent to the control board. I tested it out first as a standalone plastic part to get the geometry and placement correct, but eventually moved to integrating it into center part to reduce part count and additional hardware cost. The center part was heat staked in place, compressing the gasket in the groove, and providing a seal to prevent moisture or dust ingress.
Initial test fit for wago clips in the bottom housing
Reducing part count and taking out the additional screws, designing for DFM and how snaps would be made for injection molding
One more iteration — realizing splitting up the wagos on either side made it easier to wire connections