Next-Generation Wearable Sensor

THE CHALLENGE
A global leader in diagnostics needed to develop a complete next-generation system for an on-body wearable sensor. The challenge was twofold: design an ultra-thin, ergonomic patch to house the sensor electronics, and create a complex, single-use applicator for foolproof, painless deployment.

MY CONTRIBUTION
As a mechanical engineer on this long-term, complex program, my role was to co-develop the mechanical architecture for the entire system, with work split into two parallel streams:
Patch Enclosure Design: I worked on the external shell for the on-body device, developing the complex 3D surfacing for an ergonomic, low-profile form. My role included the mechanical integration of the client's provided electronics architecture (PCB, battery, sensor) into this miniaturized enclosure.
Applicator Mechanism Design: I also co-developed the complex, multi-part all-plastic mechanism for the deployment device. This was a deep dive into precision plastic part design, including molded-in compliant springs and material selection to ensure reliability and user safety during the one-time application process.

THE OUTCOME
My contribution was to the development of the mechanical architecture, delivering multiple high-fidelity prototypes of the wearable patch and functional prototypes of the applicator mechanism. These prototypes were crucial for validating the design's ergonomics, electronic integration, and mechanical function throughout the complex, long-term program.