english
中文
How HSY helped a UK sports wellness brand improve a wearable red light therapy device through optical optimization, thermal management, ergonomic redesign, and flexible-circuit reinforcement before mass production.
"HSY did not simply manufacture the prototype we provided. They tested the design, identified the weak points, and helped us develop a more reliable product ready for commercial production."
The client was a UK-based sports wellness brand specializing in recovery solutions for athletes and active lifestyle users.
They approached HSY with an existing wearable red light therapy prototype that required further engineering optimization before commercial production.
HSY established a performance baseline, identified root causes behind each issue, and developed optimized prototypes while maintaining the target manufacturing cost and development schedule.
The original prototype was functional but not ready for large-scale production.
- Uneven irradiance: Light output consistency decreased toward the edges of the treatment area.
- Localized heat concentration: Certain internal areas became warmer during operation.
- Weight distribution issue: Battery and controller positioning affected wearing stability during movement.
- Flexible circuit stress: Repeated folding created potential long-term reliability risks.
HSY followed a structured development process:
- Prototype performance testing
- Root cause analysis
- Engineering optimization
- Prototype verification
- Mass production preparation
HSY optical engineers optimized LED spacing and revised the internal reflective structure instead of simply increasing LED power.
Result: Irradiance uniformity improved by approximately 25%.
Under internal laboratory testing conditions, measured irradiance increased from 45 mW/cm² to 60 mW/cm² at a 5 cm testing distance without increasing power consumption.
Engineers repositioned heat-generating components, optimized heat transfer paths, and added a lightweight high-conductivity thermal spreading layer to improve heat distribution.
Result: Localized hot spots were reduced and wearing comfort was improved. Peak surface temperature decreased by 6°C under identical test conditions.
HSY simplified the internal housing, reduced controller size, and repositioned the battery closer to the center of the wearable.
Result: Total product weight was reduced by 15%, improving stability during movement.
Instead of increasing battery capacity, HSY optimized power management efficiency.
Result: Runtime increased from 2.5 hours to 3.5 hours under the same operating conditions.
The flexible printed circuit layout was redesigned and reinforced.
Result: The optimized circuit passed 10,000+ standard bending cycles without connection failure or abnormal resistance changes.
| Improvement | Result |
|---|---|
| Irradiance Uniformity | +25% |
| Surface Temperature | -6°C |
| Product Weight | -15% |
| Flexible Circuit Reliability | 10,000+ bending cycles |
| Development Stage | Prototype → Mass Production |
HSY provides engineering-led OEM/ODM solutions for global wellness and sports recovery brands, including:
- Prototype optimization
- LED optical engineering
- Structural improvement
- OEM/ODM development
- Quality-controlled mass production
From prototype refinement to commercial production, HSY helps brands create reliable, market-ready red light therapy solutions.
