Prototypes
10+ design iterations were performed to explore form, fit, material, colour, and printer types
Physical Product Design
Wave
Redesigning bone conduction headphones through 3D scanning and printing technologies to deliver a bespoke fit, greater comfort, and enhanced performance for professional athletes.
01
Overview
Project Outcome
Developed a high-fidelity appearance model through 10+ prototype iterations, using 3D scanning and Stratasys J750 PolyJet printing to combine multiple material rigidities into a single, comfortable part whilst accounting for future electronics integration
Project Information
- Role
- Product Designer
- Team
- Team of 6 Product Designers
- Focus
- 3D Printing, Prototyping, Material Testing, DFMEA
- Users
- Professional Athletes
Problem Statement
Bone conduction headphones in the current market lack personalisation and adjustability, causing discomfort for users such as professional athletes during long training sessions.
Product Requirements
- Maintain cheekbone or temple contact for effective bone-conduction sound
- Keep the design slim, ergonomic and customisable
- Combine rigid support with flexible materials for a secure, comfortable fit
- Separate CAD components and assign materials for multi-material PolyJet printing
- Plan electronics integration for manufacturing and assembly
Research Insights
- 01
Existing headphones can lift off the face during running and cycling, causing discomfort
- 02
3D scanning and printing enable a bespoke fit for each user’s ear shape
- 03
A slim profile must accommodate athletes’ helmets and sunglasses
- 04
Product autopsy suggests component placement and weight distribution may contribute to lift-off
02
Concept Development
Final Prototype
Final appearance model was tested, confirming soft, comfortable fit.
03
Final Product
A bespoke, multi-material appearance model for bone-conduction headphones, exploring personalised fit, softer contact surfaces and custom colourways for professional athletes.
