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