Medical Device Enclosure

Project Overview

Working as part of a multidisciplinary team, I led the mechanical enclosure design for a wearable biosensor aimed at continuous patient monitoring. The design had to meet strict size and weight targets, achieve IP67 ingress protection, and be manufacturable via injection moulding in biocompatible materials. Three major design iterations were informed by clinical user interviews and human factors guidelines.

Key Highlights

• IP67-rated snap-fit enclosure designed for injection moulding
• Biocompatible TPU overmould for patient-contact surfaces
• Three design iterations driven by structured clinical user interviews
• Full GD&T drawing package and material specification produced
• Final prototype mass: 34 g — 22% under target weight budget