brief
Weight budget, target feel and the non-negotiables are written down before anything is drawn.
process // brief to bench
brief to
bench
A short loop, run often. Each pass produces a physical part and a measured answer — then the numbers decide what gets redrawn.
five passes per revision
revision n+1 · fed by the last measurement
how it gets built
five passes
Nothing moves to the next stage until the previous one returned a part you could hold and a number you could argue with.
cad
Shell and structure modelled with tolerance stacks and wall-thickness limits attached.
pcb
Board outline, mounting, sensor placement and routing resolved against the same mechanical model.
prototype
Machined or printed parts, real boards, assembled by the people who designed them.
validate
Weight, stiffness, actuation and drop data recorded. Findings go straight back into revision n+1.
what each pass returns
numbers, not
adjectives
Four measurements decide whether a revision survives. Recorded on the bench, same fixture, same routine, every single time.
on the scale
Every assembly weighed before and after each change — grams are the budget, not a slogan.
under load
Deflection recorded at the shell's worst spots, so a lighter part never becomes a flexible one.
on the curve
Force and travel checked against the target feel — the switch and the shell tuned as one system.
to the floor
Repeated drops onto the bench until something gives, then the failure is designed out.
// next
bring the brief
Weight budget, the constraint that keeps breaking and the feel you are after. That is enough to start.