Product Design
Micro BLE Asset Tracker
A sub-12 mm enclosure built around flexible electronics
eNano Technologies · 2025 · 121 words · 1 min read
What
Project scope
An ultra-compact consumer enclosure designed around a flexible PCB, coin cell, copper antenna, and the practical limits of small-scale additive manufacturing.
How
Technical approach
Onshape · SimScale · FDM · SLA · Snap-fit design
Why
Outcome
The enclosure showed that a very small consumer device could remain manufacturable and mechanically robust around a tightly constrained electronics stack.
Key evidence
Process 01
Packaging the electronics
I led the mechanical design of the enclosure in Onshape. The profile uses tapered surfaces to redirect loads while keeping the tracker flat, and every internal choice was driven by the flexible PCB, antenna, battery, and minimum printable feature size.
Compact shell geometry surrounding the electronics stack.
Process 02
Prototype iterations
Early annular snap-fits worked at enlarged scale but failed at final size. I moved to a circular enclosure, tuned SLA tolerances, and used simulation to study static and adhesive loads so the shell protected the electronics without unnecessary material.
Iterative printed prototypes and fit studies.
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