Overview
This project focused on turning exposed electronic prototypes into wearable, skin-safe devices suitable for medical trials. We developed silicone casings for products including a sleep-monitoring wrist device that tracked finger twitch and heart rate response. Starting from breadboard-level electronics, we created a repeatable moulding process using medical-grade, hypoallergenic silicone. The approach also supported clear overmoulding for watertight sealing and light-transfer windows. The outcome was a reliable pathway from functional prototype to structured testing hardware.

Methodology
First, we modelled the PCB and component layout in CAD to define fit, wall thickness, and retention features. We designed a close-fitting enclosure around the electronics and produced bespoke 3D printed mould tools to validate geometry and tolerances. After confirming fit, we injected medical-grade silicone under controlled conditions and completed curing and demoulding. We then assembled and checked each unit for structural integrity, comfort, and repeatability. Each iteration refined durability and manufacturability to meet medical trial expectations.

Results Discussion
We transformed fragile electronics into robust, wearable devices ready for clinical evaluation. Medical-grade silicone provided flexibility, protection, and skin compatibility while maintaining structural strength. The mould-led approach improved consistency compared to improvised housings. We also applied the same process to create watertight seals and transparent silicone sections where light transmission was required. The key takeaway was that integrating enclosure design and material strategy early speeds up the move from prototype to trial-ready product.