PX-1 Handheld

Half the components. Zero secondary bonding operations.

SCOPE DISCIPLINES

Product design · Prototyping · Mold design

Product DesignDFM AnalysisPrototypingMold Design & Tooling

Part Count Reduction

22 → 11

Weight Savings

-28%

Assembly Steps

-45%

Prototype Cycles

6 Loops

01Overview & Objectives

The PX-1 was conceived as an ultra-compact handheld device requiring both high mechanical rigidity and high-clarity optical viewing of internal media. Conventional designs in this category relied on split-shell clamshells with ultrasonic welding seams. Our team redesigned the architecture into a unified monocoque structure with an integrated bayonet-locking transparent chamber.

02Engineering Challenge

The Clamshell Seam Problem

Split-shell enclosures create seam lines right across the user's primary grip zone. They require internal screw bosses, flex under torsional hand load, and present sealing challenges along the split perimeter.

CRITICAL TOLERANCES & CONSTRAINTS

▸Must withstand a 1.5-meter drop onto concrete across 6 orientation angles.
▸Wall thickness restricted to 1.8mm–2.4mm to meet cycle time targets under 28 seconds.
▸Optical chamber must achieve SPI-A2 mold polish without post-demold buffing.

03CAD Architecture & DFM

From Ergonomic Clay Scans to Parametric Tooling CAD

We shaped physical foam and clay mockups to lock down thumb reach and palm contour before converting the surfaces to Class-A CAD. Rib structures were engineered along primary bending vectors.

04Manufacturing & Tooling

Collapsible Core Tooling for Bayonet Lock

Rather than ultrasonically welding a threaded neck after molding, we implemented a collapsible core mechanism that forms the internal locking lugs inside the main injection cycle.

05Outcome & Verification