recon jet
sports eyewear heads-up display

ADATIVE redesigned the Recon snow optic enclosure to accommodate new display and optic hardware.

CHALLENGES

This redesign project was required due to an end-of-life manufacturing cycle for the existing micro-LCD display.  

A new display was specified and at the same time a new improved optical prism was developed.  The redesign envelope needed to no bigger than the existing optical enclosure physical geometry to ensure that there were no optic adjustment mechanical clearance issues with existing goggle partner models.  

The redesigned parts also needed to be assembled with the existing main electronics enclosure and to provide the same friction fit interference for sealing and optical alignment adjustment by the user.

OUTCOME

The result was a smaller and more tightly integrated enclosure.  The external ID surface was refined and the flexible rubber hood around the optic was converted from a U shape to a continuous loop.  DFM improvements were made to the USW assembly process to improve the weld profile and reduce process scrap.

 

ACTIVITIES \\

  • Design concepts
  • Detailed CAD specification
  • Prototyping
  • Mechanical testing and validation
  • AQL criteria for CMs
  • Review of tooling trial samples
  • Updated BoM documentation and assembly instructions

DELIVERABLES \\

  • Commercial product 

part specifications

Assembly and part drawings supplement the 3D CAD data and specify material resin, surface finishes, part colour, critical tolerances, inspection dimensions and other important annotations.


product assembly

Clear 3D printed SLA prototypes provided mechanical assembly evaluation and early water ingress testing before production tool files were released.


USW SAMPLE REVIEW

Several rounds of USW tool samples were commissioned to dial in the tools and machine setting parameters.  In addition to ensuring a quality weld between the parts the USW process also needed to prevent or limit any cosmetic damage to the parts.  The photos below illustrate some early cosmetic part marking issues that were corrected.


Final assembly instructions