Challenges in Manufacturing Wearable Devices

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From packaging to thermal management, recharging and data privacy, there are a variety of challenges in manufacturing wearable devices. Manufacturers and their design engineering teams must quickly embrace and resolve these obstacles to secure customer satisfaction, confidence and loyalty. It’s easier said than done! Let’s look at three main reasons why makers of increasingly popular devices such as smart watches, performance wear, activity monitoring bracelets trackers and GPS shoes, etc. are struggling to stay competitive.

  • The packaging puzzle: Small is beautiful for the users, but not necessarily for the manufacturer. As wearable devices become more sophisticated, their makers are challenged to package all their customers’ needs and wants into a tight design. Precision, manufacturability and the bottom line continue to be pitted against consumer demand. There is no doubt that sensors, cameras, speakers and other components have shrunk in size and increased in power. It’s the integration of all pieces of the puzzle in an aesthetically-pleasing, viable and cost-effective way that gives many design engineers sleepless nights.
  • Thermal management: Although wearable devices have made huge strides with respect to power and functionality, manufacturers are still struggling to efficiently manage the heat generated by their highly-sophisticated components. After all, it impacts user comfort and safety, system reliability, power consumption and battery life. The reality is that design and thermal management are inseparable, and the perfect balance must be figured out at the layout or conceptualization stage.
  • Battery life: Manufacturers have realized that the key to market presence is battery life. While the debate on rechargeable vs. disposable rages on, a new factor has been added to the challenge, i.e. wireless charging. Also, what works for one type of wearable device doesn’t necessarily suit another. In the end, the solution must be convenient and cost-effective for the end user. One of the greatest challenges lies in manufacturing wearable devices such as electronic clothing which must be comfortable, flexible and washable.

It is no secret that smart, cost-efficient circuit board designs are the key to the success of wearable devices. Green Circuits offers PCB design layout review to test the viability of your products. Eliminating issues at the initial stage reduces the cost and delays associated with rework. As our clients, you will enjoy advanced PCB design solutions with complete services right from material procurement, design review and assembly/manufacture to shipping and inventory management.

We have a sprawling 8,000-square foot, ESD-controlled plant that is conveniently located near San Jose Mineta International Airport to provide you with fast and efficient flex and rigid-flex circuit design, assembly and manufacturing services. We deliver special requests within 24 hours. Local pick-up and delivery in Silicon Valley is also available if you need it. Our ITAR and ISO-9000 Certifications offer you the assurance of the highest quality. We have worked with some major companies in this industry such as Fitbit, Harman, GoPro, Apple, Striiv and Intel.

Ask us for a custom PCB design and manufacturing plan to improve product quality, performance and profitability. Our team works closely with you to help overcome the toughest challenges in manufacturing wearable devices as well as reduce cost and time to market.

Request a quote for circuit boards and assembly for wearable devices. Call Green Circuits at 408-526-1700 today.