EnCata helped an early-stage health tech company develop a custom reclining pod MVP – a smart wellness hardware solution designed for workplace recovery zones. Our team handled structural analysis, actuator-driven kinematics, and full-cycle mechanical prototyping.
Industry:
Services:
TRL:
3 → 5
Project duration:
18 months
The chair's load-bearing frame must be able to hold the person's weight as well as the dome fastened to the back of the chair. A solid frame was problematic to create due to weight and dimensional constraints.
Each actuator increased the cost by 10-15%. EnCata coordinated the mechanics for unfolding the chair and the dome in time, computed the required movements.
We began the project by calculating the load frame in statics in order to determine the loads on the folding mechanism and optimize the load frame's material and design. The frame must be constructed to accommodate people of various heights and physiques. Large levers are created by the weight of a tall and hefty person, which cannot be compensated for by adding more crossbars and ribs, as this would increase the product's size, weight, and cost. As a result, we selected the cross-section of the pipe and the position of the cross pieces and reinforcements after calculating the frame loads. At the same time, we calculated each adjustment to ensure that the safety margin was enough but not excessive. Computer simulations helped us to optimize the design and choose the sufficient production techniques.
The chair's load-bearing frame was welded from a bent round tube. The chosen cross-section provided adequate structural stiffness and weight savings, while the avoidance of welding reduced manufacturing costs. Strength-testing calculations were performed in order to assure the structure's reliability.
To coordinate the chair’s unfolding mechanism, we carried out: computer simulation of the chair's operation, kinematic and force calculations of all components of the unfolding mechanism. As a consequence, the best dimensions for the mechanism components were found.
We have developed a lever system that minimized the number of linear actuators required. The levers allow you to adjust the seat inclination and unfold the footrest at the same time.
.jpg)
As a result, EnCata delivered the chair’s load frame to the Customer that met all of the requirements, as well as reliability and safety standards. The proposed solution saved from additional expenditures for installation fixtures while meeting the production cost requirements. This reduces the investment when starting production because less money is wasted on unprofitable warehouse components, organization costs are lowered, and the start-up team can do some of the work themselves because complex equipment is not required.
Master models for the pod’s key parts (dome, base, backrest) were also produced and validated at our in-house facility. The results of simulations and CAD calculations were successfully confirmed during prototyping and testing.
Need help designing and prototyping custom wellness solution? Let’s talk – contact us.
built and tested to meet all requirements
weight of the fiberglass-reinforced load frame
engineering time for design, simulation, and optimization
