Brand: ba-seus/Beisi
Name: Beisi Airpods Wireless Charging Cover
Material: silicone
Input: 5A(Max)
Color: black/red
Applicable to: Airpods

Because of 818 new product launch, some products I designed will be put on the market in a pile.
Airpods this earphone has a great effect in both design and human-computer experience, I just want to make an accessory product for it. This Airpods wireless charging cover combines protection, wire charging and wireless charging into one.
However, a series of problems also appeared in my actual design process, mainly the combination of PCBA and silica gel, and did not affect the practicality and beauty of the product. We also applied for relevant utility model patents.

At first, we imagined that PCBA Lightning heads would be welded and then put into a silica gel mold to form together. When this concept was put forward, everyone agreed that the difficulty coefficient was too high. First, we should solve the temperature resistance problem of Lightning FPC. In the process of communication with the factory, we found that silica gel was divided into low-temperature vulcanization and high-temperature vulcanization, with low temperature at 140 ℃ and high temperature at 190 ℃. This discovery

For the first set of mold T0, we only tried out 10 samples in one afternoon. After the actual assembly was Airpods, we found some problems.
1. PCBA cannot be fixed in the mold, and the silica gel will shift PCBA during vulcanization and molding, so it is found in the final function test that the effective position cannot be accurately found and the use experience is poor.

2. The opening and closing of the lid, because Airpods the original lid was very smooth at the beginning. After adding our products, the opening and closing intelligence was opened to about 30 degrees, which greatly affected the use experience. After comparing the products with simple protective covers without wireless charging function, we also found this problem;

In view of these two problems, we will continue to optimize. In the process of discussion, we imagine whether the wireless charging function can be post-processed separately and the cover and the main body can be opened together, so as to solve both the opening and closing problem and the positioning problem. In this direction, I revised the ID again and made the mold immediately after the match with the factory.

In the process of making goods, there are still some problems, such as low production capacity, defective rate of apple hood beer, difficult control of post-processing part, which is easy to cause poor appearance, testing, etc. In the end, with the efforts of all parties, especially the project manager, the products we want still arrived as scheduled.