Wearable Technology
Built for Athlete Safety.
The customer developed a lightweight impact sensor designed to integrate directly into an athlete’s mouthguard.
The device measures head-impact forces and transmits data to a sideline monitoring system through Bluetooth.
Production Challenges.
Critical Reliability.
The wearable sensor needed dependable performance in a demanding application where accurate impact data was essential.
The existing design was experiencing low manufacturing yields, field failures and inconsistent results, creating reliability concerns as the product moved toward broader use.
Reducing Stress Points.
Improving Durability.
PICA redesigned the circuit to reduce vulnerable stress points and provide greater protection for critical components.
Design Analysis
Vulnerable stress points in the original rigid-flex design were identified.
Pure Flex Conversion
The construction was changed from rigid-flex to pure flex.
Selective Stiffeners
Stiffeners and minor outline changes reinforced critical areas.
Custom Encapsulation
Rigidized areas were protected to improve component durability.
Improved field performance supported commercial release, with the technology ultimately selected for impact monitoring by a prominent international professional sports league.
