What
- Engineered a bespoke replacement shell for a multi-button car key fob, focused on comfortable handling and precise fit.
- Developed a contoured enclosure with recessed openings for three main buttons and a panic button, aligned with the internal tactile switches.
How
- Used Fusion 360 modelling and filleting to create a rounded profile that sits comfortably in the palm while staying rigid at the split line.
- Designed a reinforced key-ring loop, precise internal PCB cavities and side cut-outs for the physical key and battery access.
Results
- Delivered a model optimised for resin printing or precision CNC machining, as a premium alternative to the factory housing.
- Produced an assembly that lets the original electronics transfer straight into the new shell.
Tools and processes: Fusion 360, ergonomic surfacing, resin printing, CNC machining