Sensinel Builds and Test Fixture Improvements

Sensinel is a wearable health-monitoring platform developed by Analog Devices that combines advanced biosensing, signal processing, and edge analytics to support monitoring of patients at risk for cardiopulmonary disease. In this project, I contributed to the design and iteration of an R&D test fixture for the next-generation Sensinel device.

Yosemite Tester – Design Improvements & Contributions:
-Redesigned tester architecture to separate legs from the main body, reducing reprint requirements and iteration time during design changes
-Added a baseplate to improve tester stability and long-term durability during repeated use
-Replaced embedded nuts with tapped holes, simplifying manufacturing and eliminating the need for user presence during printing
-Designed clamp screw endpiece spacers to position wearable devices at an optimal and repeatable testing height
-Added additional constraining geometry to securely locate and restrain the wearable unit during testing
-Relocated medial and lateral attachment points to reduce required support material, significantly decreasing print time

Yosemite Tester – Build Contributions & Skills:
-Fabricated tester components using FDM 3D printing, including post-processing operations such as tapping and mechanical assembly
-Assembled electrical interfaces including banana plugs, electrodes, and a piezo board for functional testing
-Iteratively modified SolidWorks assemblies to support design changes and improve manufacturability
-Managed SolidWorks file organization to support collaboration and version control
-Tuned advanced FDM slicer settings to balance strength, surface quality, and print efficiency
-Applied precise soldering techniques for reliable electrical connections

Yosemite Wearable – Design & Manufacturing Takeaways:
-Gained hands-on experience with silicone injection casting, including mold design, surface preparation, mixing, degassing, injection, and curing
-Developed an understanding of wearable design constraints, including anatomy-driven geometry and component integration
-Learned material and surface considerations for cyanoacrylate adhesives when bonding silicone and rigid components