PDT's product designers worked with Thule to conceptualize a new iPhone case that is waterproof, dustproof and built for the adventure Thule enthusiasts seek.

Thule Atmos X5 waterproof, rugged iPhone case
Thule Atmos X5 waterproof, rugged iPhone case

Thule Atmos X5

IP Mitigation

Thule initiated an IP mitigation exercise to ensure there was no conflict with existing products on the market. A concept that featured side clips was ultimately chosen based on the sealing performance and originality.

Thule Atmos X5 waterproof, rugged iPhone case

Fitting the Needs

Sketches were adapted to CAD, with special attention focused on the case fitting the most popular audio plugs on the market (Bose, Beats, Apple, Skll Kandy, Sennheiser, Sol Republic). The mute switch design proved to be the most complex part of the design, requiring multiple iterations before resulting in a reliable, IP-68 sealed solution.

Thule Atmos X5 waterproof, rugged iPhone case

Testing Prototypes

First pass two-shot printed prototype parts were created in our on-site prototyping shop using digital material. PDT's engineers tested the functionality of the volume, power & mute buttons while also testing the grip of the back surface using these prototype cases.

Thule Atmos X5 waterproof, rugged iPhone case

Proving Protection

PDT's development team created a CNC prototype using the same production materials to test the main sealed latch design. It easily passed IP-68 testing, confirming the case's effectiveness at protecting the mobile phone completely from dust against long periods of immersion under pressure.

Thule Atmos X5 waterproof, rugged iPhone case

Perfect Execution

PDT's lead mechanical engineer for this development program traveled to China to oversee the tooling and ensure the industrial design intent and main seal design were executed perfectly.

Thule Atmos X5 waterproof, rugged iPhone case
Thule Atmos X5 waterproof, rugged iPhone case

Quality Production

Color, materials and finishes (CMF) were specified for each part, mold flow was performed to determine the method that delivered the best cosmetic finish, and a 3D manufacturing drawing was produced to ensure quality production parts.

Thule Atmos X5 waterproof, rugged iPhone case

Troubleshooting

PDT's engineering team worked along side Thule's development team in reviewing and troubleshooting challenges with first off tool (FOT) parts.

Thule Atmos X5 waterproof, rugged iPhone case

Thule Atmos X5: Stylish Protection

Thule's Atmos X5 iPhone 6/6S and 6 Plus/6S Plus cases are a stylish way to protect against drops, fingerprints and scratches without losing any smartphone functionality.

About Product Development Technologies (PDT)

Product Development Technologies (PDT) is a global, full-service product design and development firm with 120 employees worldwide. Team members have expertise in a wide range of product development disciplines, including strategy, scouting, design research, industrial design, user experience development, mechanical and electrical engineering, software development, and sourcing. PDT’s award winning product designs have been recognized with more than 70 awards from authorities such as BusinessWeek, Fast Company, the Industrial Designers Society of America and The Consumer Electronics Association.

© 2017 Product Development Technologies

PDT is a trademark of Product Development Technologies, LLC