Wireless-Wearable BioSensor Unit

A new light and low-profile biosensor was designed, prototyped and tested. The wireless-wearable sensor is specifically engineered to collect muscle activity data, offering athletes and fitness enthusiasts the means to optimize their workout routines and achieve fast, guaranteed results.

Key Features:

Thin and Light Design: The biosensor boasts a slim and lightweight form factor, making it ideal for comfortable wear during workouts. Its low-profile nature ensures a seamless fit under workout clothing, allowing users to focus on their exercise routines without any hindrance.

Low-Power Efficiency: Utilizing a small 30 mAh battery, our biosensor has been optimized to function for multiple days on a single charge. This impressive low-power performance ensures prolonged usage without interruption, providing continuous monitoring throughout extended workout sessions.

Low-Power Bluetooth Technology: The biosensor employs state-of-the-art low-power Bluetooth technology, enabling seamless and efficient data transmission to our dedicated app. The app has been specifically developed to integrate seamlessly with our hardware, facilitating real-time monitoring and analysis of muscle activity data.

Tuning Capability: Our biosensor is equipped with tuning capabilities, allowing users to adapt it to various use cases. This versatility ensures optimal performance and accurate data collection across different workout routines, accommodating a wide range of user requirements.

Customized Industrial and Enclosure Design: The entire product, including additional sensors, features an in-house industrial and enclosure design tailored to fit together seamlessly. This meticulous customization ensures a cohesive and compact unit, promoting durability, functionality, and user comfort.

Innovative Factors

This design utilizes several innovative approaches and techniques developed during the project development:

Bio sensor driver and interface: An optimal interface was designed to achieve maximum sensitivity and dynamic range from the sensor, enabling its use in various use-cases.

Efficient adaptive data sampling routine: This routine was implemented to optimize power consumption by dynamically adjusting data sampling based on the user's activity level.

Additional sensors: These sensors are incorporated to detect the correct placement of the sensor on the body and provide users with additional health-related data while using the device.

Mechanically adjustable sensor location within the enclosure: The sensor's location can be mechanically adjusted within the enclosure to accommodate individual preferences and optimize data collection.

Bill of Material and Mass Production

Below is the BoM prepared for the mass-production on the unit. Please note, the numbers are for 10,000 of built quantity.

  • Plastic enclosure covers: unit price ~$2.5

  • BLE chip: unit price ~$2

  • Sensor parts: unit price ~$1

  • PCB and other parts: unit price ~$1.5

  • Battery and charging circuitry/connector: unit price ~$2

  • Testing and QA: unit price ~$1

  • TOTAL: (high volume cost (10,000 units): $10.0

We estimate that the target cost will be around $5 when we move production offshore, specifically for quantities over 10,000 units. On the marketing side, our research indicates a target price of $99-$149 for each unit, which will provide us with a significant profit margin, taking into consideration the cost of advertisement and other expenses.

Project Duration

The objectives for this project were as follows:

  • Detailed system design, core algorithm, software, and Android application.

  • Worked on tested hardware with a final printed plastic enclosure.

  • Optimized sensor interface with the hardware.

  • Analyzed and optimized battery usage.

  • Integrated additional biosensors.

Outcome: We developed both the hardware, software, and Android mobile application.

Project duration: The project lasted for a total of 4 months, equivalent to 350 hours.