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Custom PCB Enclosure Design for Low-Cost Holter Monitor

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Taimour Zahid

Project Timeline

May 2025 - May-2025

OVERVIEW

Designed a custom PCB enclosure tailored for integration into a low-cost Holter monitor device. The objective was to combine compactness, durability, and ease of assembly with an emphasis on clean, user-friendly aesthetics. The enclosure was engineered to accommodate the PCB’s dimensional and functional requirements while ensuring reliable protection of sensitive electronic components. Alongside structural considerations, smooth contours and minimalistic geometry were incorporated to achieve a professional look consistent with modern medical-grade devices. The result was a manufacturable, ergonomic, and visually refined enclosure suitable for wearable medical applications.

HighlightS

  • Designed a custom 3D CAD enclosure for a low-cost Holter monitor, ensuring secure PCB integration, manufacturability, and medical-grade aesthetics
  • Collaborated with electrical engineering researchers to align enclosure design with medical device standards and patient usability requirements
  • Delivered a functional prototype meeting all design specifications in the first iteration, supporting ongoing biomedical device development research
  • Applied DFM principles and tolerance analysis to validate fit, clearances, and interference-free assembly

SKILLS

SolidWorks Design for Manufacturability (DFM)3D Printing & PrototypingTolerance & Fit Analysis

SUPPORTING MATERIALS

Additional Details

  • Full Design Ownership: Independently designed the complete custom enclosure for a low-cost Holter monitor using SolidWorks, from concept modeling to prototyping.
  • Material & Fabrication: Utilized PETG filament for enhanced durability and flexibility; 3D printed using a Bambu Lab A1 printer to achieve high accuracy and surface quality.
  • Battery Compartment: Engineered a dedicated bottom-cell compartment with a sliding enclosure mechanism, inspired by TV remote slots, leveraging PETG elasticity for secure yet user-friendly access.
  • Structural Integrity: Incorporated internal ribs to support and stabilize the PCB, ensuring secure mounting and resistance to operational stresses.
  • Lid Design: Developed an inward-slotted lid for a sleek, aesthetic finish without protruding handles; achieved a snug-fit, easy-open/close mechanism for improved usability.
  • Connectivity & Ergonomics: Designed precisely aligned ports for seamless connections to the Holter monitor, enabling straightforward and intuitive user operation.
  • Switch Integration: Integrated rocker switches within the enclosure, balancing accessibility with protection against accidental operation.

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