Designing Headset for Manufacturing and Assembly
Headset DFA/DFM
Goal
Understand the technicality of designing and constructing a complex product, using DFA/DFM principles to improve technical feasibility while keeping production costs minimal. Improving a base in parametric modelling an additional outcome.
My Role
The scope of the project mainly ranged from ideation, conceptualisation and product development focusing on DFA/DFM principles.
Background
This project was part of a course for parametric modelling and design for manufacturing and assembly. This brief project explored the complexities of product development and construction while a design goes into manufacturing.
Starting from the components of an existing headset, a new design was developed, with design and engineering working in tandem to ensure technical feasibility while keeping the productions costs minimal.
The User
Everyday music listeners and audiophiles. Student and working adults often listen to music while they are on the move or during studies / work.
Product Teardowns
Ideation
Ideas were generated for various elements of a headset paying attention to the design language derived in the inspirations for a premium feel. Selected ideas were sorted together to form 6 fully functional concepts. The concepts were then selected for further development.
Refinement
A selected concept was developed and then refined based on the usability and manufacturability. Attention was given to ‘DFM and DFA’ principles to figure out cheap and feasible design and production. Iterations and prototyping was essential in finding the right fitment and assembly.
Band and cup adjustments
The cup of the headset is designed to swivel around upto 90 degrees to seamlessly adjust to the head structure of the user and also for easier storage options. Mechanical details were given utmost importance to facilitate the swivel movements and maintain structural rigidity for the headset cut joint.
The cushion of the headset is designed as a replaceable component to improve repairability and modularity. The mechanical details are designed to snap the cushion in place after repairs or replacements. The cushion also hides the screws of the cup fastening.
The headset also comes with an extendable length felicitated by slides with click sound. The headset offers upto 8 different extendable lengths.
Power and Charging
The device comes with a USB C charging slot, powered by Li-Po batteries.
The tactile Power button on the headset allows the user to turn-on and turn-off the device with improved ergonomics and usability features. The LEDs provide visual feedback to the users regarding battery percentage and charging.
