<aside> <img src="/icons/globe_blue.svg" alt="/icons/globe_blue.svg" width="40px" /> OVERVIEW

</aside>

Backbone Pro: Owned design of several modules of the Gen 1 Backbone Pro, starting from late Proto, through EVT, DVT, PVT, and Ramp, in a rapid development sprint lasting 12 months.

• D-Pad: Designed the D-pad plastic (triple-shot, injection-molded PC-ABS) and carbon-pill membrane (compression-molded rubber silicone). Worked with ID and UXR cross-functional teams to determine optimal shape, texture, and force-displacement profile.
• Face Buttons: Designed all eight face buttons (ABXY, Backbone, Menu, Option, and Capture), including the plastic (double- and triple-shot injection molded PC-ABS), membranes (compression-molded rubber silicone), and metal dome switches.
• PCB’s: Owned mechanical design of all nine PCB’s, including defining the mechanical control outline (MCO), button locations, connector locations, and keep-out zones. Worked with the cross-functional teams to test and pass regulatory compliance (EMI and ESD).
• Bluetooth Antenna: Owned mechanical design, assembly, and routing of the custom antenna component. Drove design of the antenna assembly process, tools, and fixture at FATP.
• System Wiring and Interconnects: Owned wire-routing of all cables and interconnects, including working with suppliers to design a custom USB-C cable, connectors, and wire-routing die-cuts.
• Build Support and Management: Travelled to suppliers in China to oversee assembly line bring-up and qualification during EVT, DVT, and PVT. Triaged assembly issues, performed DOE’s, and performed failure analysis during reliability testing.
• Other Product Design Work: Design of the detachable pad magnetic system, critical stacks, tolerance analysis, Cp/Cpk, FAI/SPC’s, DOE’s, EFFA, and project management.

Project Page: Backbone Pro (If the link above says “No Access,” please contact me directly if you need access.)

• Project List

  • Dpad Double Press
  • Harness Hotspot
  • Antenna Routing
  • ESD/EMI
  • System Wire Routing

• D-Pad: Owned design of injection molded plastic (3k), compression-molded silicone membranes.

  • 2k and 3k ownership Tool ownership

    • Injection molding OK2tool (2k + 3k)
    • OPS laser marking
    • multiple rounds of DFM
    • poke-yoke.
    • own 2D and 3D

  • membrane

    • design
    • DFM
    • compression molded
    • force, click ratio, noise

  • Double-press issue

    • baselining with PH → comparing feel, stroke, double-press.

  • REL and lifetime testing

  • UXR review feel of d-pad golden-hands

  • ForBetter membrane qual

  • critical stack/TA of the stroke

  • Issuing deviations/waivers for all builds.

  • Engineering fit checks at EVT

  • D-pad CNC to laser cutting resulting in OOS dimensions.

• Face Buttons

  • 2k AUX
  • 3K ABXY buttons
  • multiple rounds of ID review
  • artwork deviations
  • owning all 2D
  • t0 shots
  • critical stack + TA’s
  • ID review of button heights
  • BB button gluing and light pipe → 2K version of BB button.
  • alternate vendor qual (ForBetter + PUT)
  • light-blocking for the bbb-men membrane
  • Buttton for testing on the Mark 10
  • ABXY to joystick distance.

• MCO’s

  • created all MCO’s
  • located all the connectors.
  • keepout/keepin zones for components
  • custom connector development
  • critical stacks + TA’s
  • review during compliance changes, EMI, ESD, OTA
  • mechanical REL associated with the MCO’s
  • 2D, SPC/FAI
  • TLA ownership → workflow for loading EE models + approval process
  • owned and designed all dome sheets for the aux buttons
  • LRB connector REL issue (FIND SLIDES)
  • Panelization DFM’s

• Wiring

  • RRB wire pullout
  • LRB and RRB wire length evaluation
  • X-Rays of wiring (SHOW routing consistency)
  • baffle and pusher design (Show rapid mitigations)
    • Show shitty die cuts
  • battery acetate tape → battery wires too long resulting in cert issues.
  • wire pinched in bridge
  • Pre-bent shrinkwraps
  • custom no-ear connectors
  • USB-C Harness
  • Mechanical Control Outline for all PCB’s: Connector locations, keepout zones.
  • Custom B2B connecotrs
  • Wiring, Interconnects, and Routing

• Antenna

• Tunnel Caps

• Builds:

• General

NIJI _ PVT_ USB-C Harness Hotspot.pptx

Niji USB Harness.pptx

NIJI _ prePVT_ Wire Routing.pptx

Patrick_Working_Deck_Q12025.pptx

Niji_PCB_and_Cable_Routing.pptx

Niji_Pat's_Working_Deck_Q2-Q42024.pptx