Fitness Wearable

Led hardware design of a next-gen wearable, combining user-ergonomics with integrated biomedical sensing.

Role

Engineering Contractor

Industry

Consumer Electronics

Duration

6 months, Ongoing

Pre-production design 1
Pre-production design 1
Pre-production design 1

Overview:

Fort is a next-generation wearable engineered to quantify muscular fatigue with clinical-grade precision. It houses a sensor suite that features four gold-plated surface electrodes for multi-axis EMG, alongside an optical stack with near-infrared (NIR) sensors, photoplethysmography (PPG) sensors, and pulse oximetry. A fully integrated IMU enables motion insights that is contained within an IP67-rated enclosure.

Overview:

Fort is a next-generation wearable engineered to quantify muscular fatigue with clinical-grade precision. It houses a sensor suite that features four gold-plated surface electrodes for multi-axis EMG, alongside an optical stack with near-infrared (NIR) sensors, photoplethysmography (PPG) sensors, and pulse oximetry. A fully integrated IMU enables motion insights that is contained within an IP67-rated enclosure.

Preproduction design 2
Preproduction design 2
Preproduction design 2

Key Contributions:

  • Owned the full-cycle hardware design integrating EMG, PPG, pulse oximetry, IMU, and NIR sensors into a streamlined wearable.

  • Designed ergonomic user interfaces including tactile button mechanisms and strap systems for optimal comfort and usability

  • Designed IP67-compliant housing with custom gaskets and radial seals, balancing tight environmental sealing with manufacturability.

  • Partnered with contract manufacturers to source and qualify custom injection molded and CNC-machined parts for low

    volume (250 units) beta production.

Impact:

Delivery of ruggedized pre-production prototypes, optimized for manufacturability and manual assembly while maintaining user comfort and a high quality feel.

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Zachary Valles

Copyright 2025 by Zachary Valles

Zachary Valles

Copyright 2025 by Zachary Valles

Zachary Valles

Copyright 2025 by Zachary Valles