Call Us 24/7
+91 6357173693
Send Us Mail
business@imacengineering.com
The goal was to create an intelligent pillcap that uses SIM‑based cellular connectivity to reliably notify both patients and doctors when doses are missed. The design needed to be robust, cost-effective, and easy to manufacture—transitioning from glue to snap‑fit assembly, while maintaining seal integrity and protecting internal electronics.
A clear visual interface was also essential: a single light pipe indicating two distinct LEDs. Finally, the cap required a tamper-evident mechanism that would break if opened improperly, without risking PCB damage.
Several hurdles emerged. The original glued assembly was unreliable, slow, and inconsistent. The seal‑disc failed under repeated use. Light from dual LEDs leaked and scattered, reducing clarity.Snap-fit mold design risked shrink marks and could over-compress the internal PCB if not engineered carefully.
Moreover, introducing a tamper feature that didn’t impact assembly or leak paths added complexity. Choosing the right materials and maintaining tolerances further complicated the design.
.webp)
To address these issues, we implemented snap‑fit joints, increasing size and reducing count to ensure robustness and repeatability. We adopted a rib-supported cantilever snap-lock for sealing—drawing on best practices to taper and fillet the cantilever, minimizing stress concentrators and mold shrinkage The cantilever ribs prevented sink marks while maintaining sealing force.
For optical indication, we designed a single light pipe with internal reflective surfaces to guide two LEDs independently, reducing bleed and improving visibility. Snap-lock tabs secure the light pipe in alignment. A sacrificial snap feature was engineered to visibly break if tampered with. Snap arm geometry was tuned (taper, width ≥ 5 mm, lead-in angles, fillets) to balance retention force and avoid stressing the PCB . Material selection and design tolerances ensured predictable mold shrinkage and reliable engagement . Prototype cycles included FEA and simulation to validate insertion/extraction and stress distribution
The redesigned pillcap achieved significant improvements: fewer, larger snap‑fits cut material and assembly costs; snaps enabled faster, consistent assembly; rib-enhanced seals passed repeated cycle testing with no failures or shrink marks.
The light-pipe now clearly shows two distinct LEDs with minimal optical scatter. The tamper-evident snap efficiently breaks upon intrusion without excessive force, safeguarding the electronics. Controlled snap design prevented PCB compression. Overall, the product is smarter, more secure, and cost-efficient—meeting client specs and production standards, while leveraging industry best practices for snap-fit durability and mold reliability.
Innovative design solutions across industries
Download Brochure
