Services
Product Design
Prototyping
Material Testing
Electric Circuit Development
Injection Molding
User Testing
R&D
Mechanical Engineering
Electrical Engineering
Technology
CNC Machining
Flexible LED Panels
TPU Materials
PET Flexible Circuit Boards
UV Curable Solder
Injection Molding
Power Supply Circuit Design
Outshining the Competition
The Challenge
The client needed a breakthrough in tooth-whitening comfort while keeping the design sleek and cost-effective.
Our client recognized an opportunity to innovate in the tooth-whitening market by developing a device that significantly enhances user comfort. With consumer expectations evolving and competition increasing, they aimed to create a next-generation product that would set new standards for comfort, aesthetics, safety, and cost-effectiveness. The challenge was to design a tooth-whitening device from the ground up that fits comfortably in the mouth while delivering exceptional performance.
A Bright New Approach
The Solution
Innovative materials and prototyping led to a comfortable and effective whitening device.
Zaic Design approached the challenge by leveraging our capability to rapidly design, prototype, and test iterations, enabling swift and informed decision-making. Our comprehensive in-house design services allowed us to progress quickly through various stages of development.
The client desired a device where the LEDs would illuminate both inward and outward to enhance functionality and provide an attractive aesthetic effect. To achieve this, we meticulously designed the electrical traces on the circuit board for both optimal performance and visual appeal. This required a careful balance between engineering efficiency and aesthetic considerations.
Our initial concept involved over-molding a transparent TPU material onto flexible LED panels, aiming for a comfortable fit without compromising performance. We began by designing and CNC machining aluminum molds and collaborated with a plastics supplier to test this approach by producing several hundred assemblies. Early prototypes included room-temperature molded flexible lenses to validate our design direction.
Early room-temperature molded flexible lens prototype.
During testing, we discovered that the existing LED panels couldn’t withstand the heat from the over-molding process. This prompted us to pivot and design a new flexible LED panel capable of enduring both thermal stress and the mechanical demands of mass production.
To fulfill the client’s desire for LEDs that illuminate in both directions and achieve a fully transparent product, we explored transparent PET flexible circuit board materials. Traditionally, soldering components onto such materials requires heat, which could damage or deform the PET substrate. To address this, we collaborated with Sunray Scientific who helped develop a solution using UV-curable solder. This innovation allowed us to make electrical connections at room temperature without harming the PET circuit board.
PET flexible circuit board with Sunray Scientific’s UV-curable solder for low-temperature soldering.
We also developed a USB-C power supply circuit board that allowed the device to be controlled by both Android and Apple devices and that included multiple session timer options. The electrical traces were meticulously designed to optimize performance while enhancing the device’s visual appeal, contributing to an attractive overall design.
To further streamline the prototyping process, we invested in a small injection molding machine. This allowed us to rapidly iterate the device’s form, producing numerous prototypes for testing and refinement.
See the Prototype in Action: Click here to watch a brief video demonstration of one of the prototypes being used.
One of many iterations produced rapidly through in-house prototyping.
Our ability to design, prototype, and test quickly allowed us to explore multiple design directions efficiently for our client.
A Brilliant Finish
The Outcome
The final product exceeded client expectations and reached the market quickly.
The outcome was a sleek, comfortable device that met all design criteria, including enhanced user comfort, safety standards, and cost-effectiveness. The prototypes underwent rigorous testing and were refined to meet the client’s exact specifications. We completed the engineering phases in under a year—significantly faster than typical project timelines.
The final design was transferred to the client’s in-house manufacturing team and has since been brought to market, receiving high customer ratings and excellent reviews for comfort and effectiveness.
Lighting the Path Forward
Future Development
The success of this project is just the beginning of a lasting partnership.
The success of this project has paved the way for continued collaboration. Zaic Design is now involved in developing the next generation of this product, continuing to innovate in the field. We are excited to push the boundaries of comfort and technology in future iterations of this and other devices.
Our commitment to innovation and user-centered design makes Zaic Design a trusted partner for companies seeking to develop cutting-edge consumer products that seamlessly integrate technology, comfort, and functionality.
With expertise in product design, material selection, prototyping, and iterative engineering, we specialize in overcoming complex challenges in consumer device development. Our capabilities in automation integration allow us to offer scalable solutions that enhance both product development and manufacturing processes.
Whether you’re looking to advance your product line with innovative designs or explore automation solutions to streamline production, Zaic Design has the technical acumen and creativity to drive measurable success. Our automation expertise extends beyond production line enhancements—offering the potential to integrate automation into your product designs themselves, paving the way for smarter, more efficient devices.
Schedule your free consultation today and discover how Zaic Design can revolutionize your product development and manufacturing processes with industry-leading design and automation solutions tailored to your needs.
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