A client from the wireless headset industry for scooters and motorcycles approached me to adapt the technology for cyclists. The project required a unique design and integration of wireless communication technology, which I accepted as an exciting challenge.

I started by setting up design guidelines:

• Preserving the client’s industrial design vision

• Ensuring the headset could attach to either side of a helmet

• Creating a flexible BOOM to connect the headset and microphone to the electronics, allowing easy adjustment

• Meeting the client’s specific speaker and microphone requirements

I divided the project into mechanical and electronic components and began the design process. I created a rubber keyboard with tactile pressing membranes for a responsive feel while riding. Additionally, I designed a 210-degree rotating mechanism for the microphone holder, enabling attachment on either side of the helmet. After collaborating with an electronics engineer, I produced the first circuit and assembled the initial model, presenting three units to the client.

Based on rider feedback, I made adjustments, including adding electronic cards for easier wiring, enhancing the microphone holder rotation, and adding air filters. I then produced seven more models, which became the “gold series” prototypes.

The client approved moving to mass production, so I initiated the design for manufacturing (DFM) process with the support of a factory in the East. I designed and approved molds for all parts, prepared a full bill of materials with pricing, created an ATP for the production line, and tested the first production series.

The production involved various processes, including plastic injection molding, over-molding rubber onto plastic, insert molding, and CNC machining. The system is set to be released in December 2022, and it has already received thousands of pre-orders from global customers.