Gyration
Ultra Cordless Optical Mouse
Extremely Tight Packaging Constraints
 The Gyration Ultra cordless optical mouse is a breakthrough performance product. Gyration, the world's leading developer and manufacturer of gyro based input devices turned to IDE for the detailed product design and mechanical engineering of this new flagship product. The Gyration Ultra is a excellent example of how IDE tailors its capabilities to suit the needs of its clients.

Unlike the GyroRemote product, in which IDE was retained for the industrial design, ergonomics, 3D CAD and product branding, Gyration came to IDE with an existing concept and industrial design for the Ultra. IDE joined the Gyration development team to provide the detailed product design and mechanical engineering. Gyration had a very aggressive schedule for the development of the Ultra and there were several mechanical challenges to tackle, including very tight packaging constraints to achieve the desired ergonomic form factor.

Evaluation And Refinement

The Ultra's compact rounded form had to accommodate Gyration's proprietary solid state gyro sensor, radio electronics, optical sensor and associated electronics, LED's, buttons and trigger switches, scroll wheel and rotary sensor, and two battery pack options (one that uses Alkaline batteries and one that uses rechargeable batteries). All of these components had to be packaged into the tiny mouse form factor without compromising the industrial design.

IDE's design engineering team began the project by evaluating the exterior surfaces that defined the Ultra's exterior form. IDE's design team conducted surface analysis of the imported surfaces and implemented subtle refinements to address issues of surface smoothness (resolution), draft (taper) for the plastic injection molding process, and mold parting lines. These surface refinements were then sent to Gyration for review and approval.

The design team's next task was to complete the product design and mechanical engineering, developing a 3D solids model of the entire design using Pro Engineer. The solids model assembly would include all PCBs and electro-mechanical sub-assemblies and components, as well as all custom plastic parts, buttons, latches and battery packs . IDE's mechanical design engineers worked closely with Gyration's electronics design team to determine the final form factor and component placement for each of the internal electronics PCBs (radio/gyro board and digital/optics board).

Concurrent Design Effort

While one member of IDE's design team worked on the PCB packaging, another began work on the detail design and engineering of the plastics including the large, hinged key buttons and internal structural elements. A third design engineer focused on the design of the two battery packs, a sealed rechargeable pack and a pack with identical form factor that would accept three AAA Alkaline batteries. In addition to using common plastic parts, the two packs had to be designed so that the user could simply exchange one for the other and not have to worry about the charging circuit trying to charge the Alkaline cells. IDE solved the problem by designing custom battery charging contacts that could be manufactured from a common tool, yet configured for either rechargeable or non-rechargeable applications.

Interactive Design Reviews

IDE and Gyration were able to work interactively, utilizing web based visual/teleconference design reviews to review developing designs on a weekly basis. This method of close communication, plus occasional face to face reviews at Gyration made it possible to complete the initial product design and engineering (prototype ready production intent design) in less than 4 months time.

IDE's design team assisted Gyration in the evaluation of the working prototypes and implementation of final revisions prior to releasing the design for production tooling, which would be developed by Gyration's manufacturing partner in Asia. Since the detail design and engineering of the Gyration Ultra, IDE has once again been retained to assist Gyration with design of another new Gyration product.