Selection of safe and secure materials

In a wearable development project with a certain company, we developed a device that is worn on the human body to constantly monitor the body's condition. In this case, reducing the risk of allergic reactions was an important issue when selecting materials for the parts that come into direct contact with the skin. We proposed materials with a proven track record in medical applications, and achieved both safety and comfort when worn.

In selecting this material, we negotiated directly with the manufacturer and found a resin material that was not only gentle on the skin, but also had the right balance of softness and strength, which made it possible to design a wearable device that could be used safely by everyone from babies to the elderly. Furthermore, we conducted repeated tests to ensure that the material would not deform or discolor due to sweat or sunlight.

Through these efforts, we have been able to create high-quality wearable devices that put the health and safety of the user first.

Realization of long-term continuous operation (low power consumption)

Furthermore, we actively worked to reduce the power consumption of the sensor module, aiming for stable operation in the field environment and long periods of continuous operation on a single charge. In particular, by adopting an ultra-low power consumption CPU, for which Macnica is a distributor, we have succeeded in significantly reducing power consumption while enabling the sensor to operate continuously.

In firmware design, many issues arose regarding elements directly related to power consumption, such as optimizing operating modes and sleep control. However, thanks to the Company technical support and a collaborative structure involving the manufacturer's engineers, we were able to provide consistent, high-quality support from the early design stages through to the mass-production phase, enabling us to achieve the low power consumption that the customer was looking for.

In addition, when it came to selecting the battery, we were faced with the unexpected situation of the battery that we had initially planned to use suddenly becoming unavailable, but we quickly proposed and procured alternatives from battery manufacturers around the world, minimizing design changes and avoiding project delays. This ability to communicate with manufacturers around the world and to respond flexibly and quickly is one of our capabilities.

Comfort supported by electronics

As extreme heat has become the norm in recent years, fan-equipped workwear has become widely used by field workers and outdoor enthusiasts as a way to prevent heatstroke.

Fans and control units do not simply send air, but must precisely control the volume of air and the timing of operation according to the environment in which they are used. To increase user comfort, smart environmental control, such as "strong wind while working and quiet mode during breaks," can be implemented in conjunction with multiple sensors to automatically adjust the fan's operating mode according to temperature, humidity, and movement, greatly reducing user stress.

Taking into account that each user's preferences and work environment are different, the control logic incorporates a customization function that links with a smartphone app, and a mechanism for updating firmware via Bluetooth communication is included, making it possible to continuously improve functions in response to feedback from the field.

Robust and unbreakable in harsh environments

The electronic products used in these products are expected to be used under harsh conditions, such as direct sunlight in midsummer, dust, sweat, and even impacts from drops. Therefore, the circuit boards must be designed with waterproof and dustproof coatings (conformal coatings), and must also have thermal protection functions that detect and automatically control temperature rises, taking into account continuous operation at high temperatures.

In addition, we use flexible printed circuits (FPCs) that are resistant to breakage even when subjected to vibration or impact, carefully selected highly durable connectors, and thorough fail-safe designs in firmware to prevent malfunctions, ensuring robustness from both the hardware and software sides.

In addition, improved waterproof performance is becoming essential for wearable devices. Monocon® has collaborated with researchers at industrial testing facilities to devise a structure that can withstand sweat and rain from the mold design stage. Although we had trouble with water getting in from unexpected places every time we conducted a water resistance test, we were able to secure waterproof performance equivalent to IPX7 and succeeded in creating a device that can be used safely for long periods of time even when working outdoors.

The design makes it easy to wear, making you want to wear it

In order for wearable devices to become more widespread, it is essential that they are not only highly functional, but also that people "want to wear them." As mentioned above, recent products place emphasis on being gentle on the wearer, such as using materials that reduce the burden on the skin, anti-allergy resins, and waterproof designs with an IPX7 rating or higher, but there have also been improvements in their smart appearance and lightness when worn.

​Monocon® realizes stylish exteriors that resonate with the user's sensibilities by inviting designers who have worked on well-known products to the project. Furthermore, by collaborating with manufacturing partners who can faithfully realize the design, it is possible to develop products that are both functional and beautiful.

If the device has a stylish design and does not look like a typical medical device, children will not feel embarrassed to wear it all the time. In childcare facilities, sensors are built into stuffed toys so that children can wear them without feeling uncomfortable.

As an example, we created a mock-up of smart glasses, as shown in the photo below.We started by asking a designer to draw a design, shared the final image with a rendering, and produced a mock-up using a 3D printer, which turned out to be satisfactory. Youcan also add special touches to the mock-up. In this example, we devised a paint scheme to pursue a color that would bring the smart glasses closer to their final form. The glass part was painted bluish black, and the color was adjusted to create a metallic look, while the band part was given a matte finish with a different texture. We can incorporate various requests to create something that is closer to the actual product image.

Design drawing

Rendering

Mockups made with a 3D printer

"Proactive safety management" achieved through sensors, cloud computing, and AI

Macnica 's cloud technology also supports systems that link vital data and environmental information collected by sensors to the cloud in real time, and immediately notify administrators of alerts when abnormalities are detected. Unified management of sensors and the cloud eliminates variations between sites and serves as the foundation for optimal safety measures.

In addition to real-time warnings, AI can also analyze accumulated vital signs data to predict which times and tasks are dangerous.

For example, on one production line, it became clear that the risk of accidents tended to increase after lunch breaks, and by moving work hours forward, the accident rate dropped significantly. Sensors are no longer just monitoring tools; they are also beginning to demonstrate their value as tools for predicting the future. Accumulating data and making predictions makes it possible to move towards "proactive safety management."

Integrated support from procurement to mass production

In terms of parts procurement, we also handle overseas procurement and overseas manufacturing (so-called OUT-OUT) with a view to the global market. In preparation for supply instability due to climate change and geopolitical risks, we have established a system that allows us to flexibly respond to sudden supply disruptions by securing procurement routes from multiple regions both domestically and overseas in advance.

In addition, even during the mass production phase, we can build an overseas manufacturing system in cooperation with local EMS. By optimizing the integration of circuits and housings, taking into account mounting ease and assembly man-hours from the design stage, we can smoothly carry out inspections and start up mass production locally. Our overseas mass production know-how for a wide variety of products and small lots supports both cost competitiveness and supply stability.

In this way, rather than simply accumulating technologies, we have firmly established a design philosophy that deeply understands the on-site environment, and an ecosystem of development, procurement, and manufacturing that supports this.

If you are having trouble developing wearable devices, please contact Monocon®.

"I don't know where to start technically."
"The specifications have not yet been finalized, but I would like to consult with you from the concept stage."

We can help even at that stage. Delivering the best technology to those who need it without any hassle. That is the starting point of our support for manufacturing. As a"reliable partner"for companies taking on the challenge of developing wearable devices, we continue to support them from conception to implementation and mass production with our reliable technology and flexible response capabilities.

If you are having trouble developing a wearable device, please contact Macnica Monocon®.

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