MC10 Inc.

During my time with MC10 Inc., a notable project that I had a major role in was the Lightning Band proof of concept project for a major sportswear company. When I joined MC10 I immediately went to work on this proof of concept project since it was on a promised tight timeline.  It was early stages for the growing MC10, so it was crucial to impress the customer.  The proof of concept task was to construct a stretch limiter integrated into the stack-up of a black silicone molded band 150mm long by 15mm wide by 2mm thick that protected a copper and polyimide electronic serpentine (shown below) with several LEDs.  The electrical components were nearly complete, but the stretch limiting portion of the stack-up that we needed to protect the delicate internals was at square one when I joined.  The thickness of the stack-up was already at about 1.5mm out of 2mm without a strain limiter, thus adding to the challenge.    

Several options were brainstormed and tested, but it was crucial that the stretch limiter was hidden and unfelt until the user approached the 30-40% elongation mark.  After going through several tests, an ideal solution and manufacturing procedure was found. The ideal solution adhered well with the silicone stack-up without delamination, was easily implementable for manufacturing, and protected the delicate electronics, all while allowing conformability (ie. bending, twisting, stretching).  Intellectual property was filed and a presentation was made for showcasing to the customer who was very pleased with the final result.