alpine ski goggle heads-up display redesign
ADATIVE redesigned the Recon snow optic enclosure to accommodate new display and optic hardware.
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 to ensure that there were no mechanical clearance issues.
The redesigned parts also needed to be assembled with the existing main electronics enclosure to provide consistent assembly, sealing and user adjustment.
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.
- Design concepts
- Detailed CAD specification
- Mechanical testing and validation
- AQL criteria for CMs
- Review of tooling trial samples
- Updated BoM documentation and assembly instructions
- Commercial product
This side-by-side comparison shows an early Snow2 Optic Enclosure industrial design concept. This concept was further refined as the detail design was resolved and DFM reviews were received from the injection moulding and USW tooling contract manufacturers.
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 for manufacturing and quality.
Clear 3D printed SLA prototypes provided mechanical assembly evaluation and early water ingress testing before production tooling 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.