Coil Earphones
Earphone Concept Development (2024)
The Coil Earphones project is a concept development study focused on form-giving and ergonomics through the use of rapid prototyping and 3D printing. This project builds on a previous concept study, which emphasized rapid ideation and producing concept proposals. In 2024, I revisited this earlier work, aiming to improve and modernize it, incorporating current technological advancements in noise-cancelling Bluetooth earphones.
The updated design retains elements from the previous versions but significantly enhances ergonomics and fit. The outcome is a concept proposal that has been extensively tested for comfort through multiple 1:1 scale model iterations and in-ear testing.
This is an ongoing project that will be updated frequently. Please feel free to return for further materials and information.
Keywords: Concept design, ideation, rapid prototyping, ergonomics, 3D printing, form-giving
Background
The development of this project began in 2019 during a design concept sketching and ideation course. As part of the course, I undertook a common industrial design exercise: generating 100 sketches for a product, which in this case, was earphones or headphones. Over a few days, I produced more than 150 proposals, which were then narrowed down to two main concepts. These two designs were selected for their unique forms and details, as well as their feasibility for production.
After the course ended, I revisited the concepts to further develop them. I created 3D models of both designs using SolidWorks and rendered them into presentable visuals with KeyShot. This allowed me to visualize the concepts in more detail and refine their forms, leading to more polished proposals.
Product renderings of the two chosen and refined design directions (2020)
Coil Concept Development
The motivation to update this project came from a playful desire to experiment with my newly acquired Bambu Labs X1C 3D printer. This provided an opportunity to explore how 3D printing could be leveraged for rapid prototyping. My previous experience with earphone design was the perfect fit for testing ergonomics driven development with 1:1 scale models, printed quickly using the X1C.
For form-giving, I retained some design details from the earlier versions while focusing primarily on ergonomics. A key design feature was the inclusion of the familiar "stick" part, as seen in products like Apple’s AirPods, which I personally prefer for ease of handling and tactile feel.
Ergonomics-Driven Ideation & Rapid Prototyping
The process began with loose ideation sketches, which were quickly translated into 3D software to create the first rough models for 1:1 scale prototyping. The general dimensions were accurate from the initial test model, allowing for swift refinement of finer details and shapes to optimize ergonomics. The forms evolved naturally from this ergonomics-driven prototyping process.
The back of the design features a slight slope for better grip, while a circular metallic detail adds a jewelry-like touch. In a final product, this element could house an engraved brand logo for a polished, recognizable look. During this stage, attention was also given to designing parts and structures that would be suitable for injection molding and mass production. However, close collaboration with engineers and manufacturers would be essential to ensure that each part is optimized for efficient manufacturing.
3D printed 1:1 rapid prototyping models
Forming the Earpiece and Ensuring a Comfortable Fit
One of the key challenges was designing a fit that was both snug and comfortable, while also accommodating the requirements of noise-cancelling technology. In order for the noise-cancelling feature to function effectively, the ear canal must be adequately sealed to prevent background noise from leaking in. Achieving this balance between a secure fit and comfort was critical.
Through multiple rounds of iteration and testing, I refined the inner earpiece design and overall dimensions of the earphone. The iterative process involved modeling and printing one or two variations at a time, testing them personally, and then adjusting the designs accordingly, repeating this cycle until the ideal fit was achieved.
After extensive rapid form exploration and prototyping, I proceeded to create a high-definition version of the concept. The final design incorporates the most ergonomic forms, while addressing both the technical requirements of noise-cancelling technology and the overall usability of the product.
In-ear prototype testing
Rapid modeling for prototyping and testing (left) high-definition concept model (right)
The Concept
The final design features a light stone colorway with fine aluminum detailing. The back resembles a speaker coil, reinforcing the earphone's function as a music device while adding a jewelry-like shine when worn. The organic forms follow the natural contours of the ear, and the circular detailing gives the design a timeless, uniform aesthetic. A physical button is included for controls, as I believe tactile feedback offers a more premium experience compared to the oversaturation of touch-based interfaces in the market. The visual expression of the product strikes a balance between premium quality and approachability, positioning the design between similar products from brands like Sony and Bang & Olufsen.
As the project is ongoing, it will be updated with animations, alternative colorways, and additional detail shots. For further information or inquiries about the design, feel free to contact me. Stay tuned for future updates.
