Wearable Brain-Computer
Client country: China
Services: industrial design｜machine design｜functional prototyping｜packaging design｜mold development
Project Background
Solution
Wearable Brain-Computer Interface Design Innovation
A. Size Adaptive Adjustment Solution
To fit different head circumferences of children aged 5–12 and even adults, a segmented adjustable buckle with a scale marker structure is adopted:
The main body uses a multi‑segment flexible connection, enabling stepless adjustment within a 12 cm range via a sliding buckle, with precise positioning through scale markings to cover head sizes of all age groups.
The adjustment knob features a large, non‑slip texture for easy operation by both children and parents, preventing accidental adjustments.
Medical‑grade elastic hinges are used at joints to ensure a snug fit while avoiding pressure on the head.
B. Interactive Lighting Interface Solution
An intuitive user experience is realized through a visual status lighting system:
A ring‑shaped diffused LED light strip indicates different working statuses with distinct colors:blue for working / intervention mode, green for fully charged, red for low battery alert, allowing users to quickly identify status at a distance.
The lighting uses soft diffusion technology to avoid strong light irritation to children’s eyes without affecting daily study and rest.
The lighting system links with the APP to support basic status indication for clear and easy understanding of core functions.
C. Safe Materials and Protection Solution
A full‑chain safety and protection system is established based on children’s health, environmental protection and practical scenarios:
- Skin‑contact parts are made of maternal‑infant grade liquid silicone, certified by EU REACH, China GB 4806 and other safety standards, being odorless, non‑irritating and suitable for children’s sensitive skin.
- The outer casing uses biodegradable bio‑based plastics to reduce environmental impact, while providing excellent drop resistance and stain resistance for daily use by children.
- All internal components use lead‑free soldering, and packaging materials are recyclable pulp, fully meeting environmental standards.
- The product achieves IPX4 water resistance, protecting against daily splashes (e.g., hand washing, accidental rain exposure) and improving adaptability and durability.
- The total weight of the product is controlled at 150g, balancing structural strength and wearing comfort with no obvious pressure during long‑term use.
D. Child‑Friendly Experience Optimization
- The appearance features a rounded, edge‑free design to prevent injuries from bumps. Fresh white and light blue color matching is used to reduce medical‑device perception and improve children’s acceptance.
- The operation logic is simplified with only core function buttons, supported by lighting prompts to lower the learning curve for both parents and children.
- The wearing structure fits the physiological curve of the forehead to distribute pressure evenly, without interfering with children’s daily activities and study.
Wearable Brain-Computer Design Process
Stage 1: Demand Research & Analysis
Stage 1: Demand Research & Analysis
Core Goal: Clarify user pain points and design indicators to provide a basis for design.
- Conduct user and competitor research to clarify the head circumference, comfort, safety and waterproof needs of all age groups, and determine differentiated directions such as 12cm adjustment and IPX4 waterproofing.
- Sort out medical-grade, material safety and children’s product-related standards, and output a demand specification to clarify core design indicators.
Stage 2: Concept Design
Stage 2: Concept Design
Stage 2: Concept Design
- Conceptualize a segmented flexible structure, 12cm stepless adjustment and 150g weight distribution, and determine the forehead-wearing method.
- Clarify the circular LED light status logic (blue = working, green = fully charged, red = low battery) and simplify the operation layout.
- Screen maternal-infant grade silicone and degradable plastics, plan the IPX4 waterproof structure, and determine the optimal plan after review.
Stage 3: Detailed Design
Stage 3: Detailed Design
Stage 3: Detailed Design
Stage 3: Detailed Design
- Draw 3D models, refine the adjustment structure and IPX4 waterproof sealing design, and ensure comfort and strength under the 150g weight.
- Confirm the selection of materials and components to ensure compliance with safety certifications, and output design drawings, BOM lists and other documents.
Stage 4: Prototype Production
Stage 4: Prototype Production
- Produce 1:1 mock-ups and functional prototypes to verify size adjustment, wearing fit, lighting and waterproof functions.
- Complete basic testing, record and initially sort out problems such as adjustment jams and wearing pressure.
Stage 5: Testing & Optimization
Stage 5: Testing & Optimization
Stage 5: Testing & Optimization
- Complete material safety, IPX4 waterproof and electrical safety tests, and invite users and doctors to verify adaptability and comfort.
- Iteratively optimize the design for test problems and complete compliance verification and document sorting.
Stage 6: Design Finalization & Mass Production Preparation
Stage 6: Design Finalization & Mass Production Preparation
Stage 6: Design Finalization & Mass Production Preparation
- Summarize test results to determine the final design and improve various documents required for mass production.
- Coordinate with manufacturers to optimize production processes, assist in production line commissioning and sample inspection, and review design experience.
The entire process is centered on user needs and takes safety as the bottom line to ensure the product is suitable for both children and adults and meets medical-grade and environmental protection requirements.
Value
This project won three international design awards.
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