• 2.5mm stereo headset
• built-in microphone
  
• USB PC Data interface
• 32MB SD/MMC Memory Card
• 3.5mm to 2.5mm headset adapter
• drag and drop file transfer via USB with included Motorola MUSICMATCH software

Scope of Design:

• Industrial Design Liaison
• Mechanical layout and design
• protoyping and manufacturing support

The Challenge:

Overall product size was the driving factor for this product. An extremely small form factor was determined at the outset and many innovative design solutions were developed to maintain this constraint. The surfaces were quite complex and the requirement that the product have soft-touch over-molding in contrasting color made for a very complicated parting line between the various housing components. Also, the design team had members in England, Chicago, San Diego, and Korea, so collaborative discussions were often a challenge.

The Result:

Mechanistic developed a mechanical layout of all the internal mechanical components as well as the SD card audio jacks to be inserted into the unit. The maximum size constraint was so aggressive that many internal components required localized thinning of the housing wall thickness to provide clearance! After several machined check models and design reviews the detailed CAD parts were delivered to the overseas manufacture. Total design time: less than three months!