Feature title.
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).
Integrated electronics and display
Custom PCB, display selection and integration, and flex cable routing packaged into a slim caliper body. Built for clean assembly, durability, and easy service access
Multi mode precision measurement
Precision linear sensing architecture for accurate jaw travel, plus a rotary wheel for curved surface distance. Front ToF sensing enables quick no contact spot measurements
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.
Unibody aluminum chassis, top side packaging
Machined aluminum unibody with a dedicated display pocket and button openings. The top side defines the user touch points and locks in the screen position for a clean, flush fit.
Bottom Side For PCB Assembly
The underside of the unibody is the main mechanical datum for assembly. It provides the PCB mounting shelf, alignment features, and clearance for internal components so the electronics drop in cleanly and stay rigid.
Fully Functional Calipr Prototype
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.
