Below is a brief documentation of my process of designing and engineering of the Calipr, a modern take on the decades old vernier caliper. I was directly responsibly for the industrial design, CAD, electronics (PCB design) and component integration (connectors, display, actuators, magnetic sensors and calibration).
Unified Electronics Architecture
I architected, designed, and integrated Calipr’s full electronics into a single main PCB, consolidating the display interface, sensing, power, and user controls into one assembly. This reduced part count and connector complexity, simplified manufacturing and test, and improved reliability while meeting the tight mechanical envelope of the caliper body.
I worked with overseas contract manufacturers to build Calipr end to end, from CAD and schematics to finished parts. I released production ready files for the machined aluminum chassis and plastic components, including GD&T, tolerance stacks, surface finish and anodize specs, and DFM iterations based on fit and inspection results. In parallel, I managed PCB and flex requirements for the display and precision linear magnetic sensor.
