On April 27th, Martine Stillman (Synapse Mechanical Engineer Program Lea
Synapse helped Sol Republic realize their innovative design for the Shadow Wireless Headphones. Our mechanical engineers worked with the selected Contract Manufacturer to tackle technical challenges posed by the Industrial Design. The mechanical architecture the Synapse team developed demonstrated all the components could fit in the targeted Industrial Design while maintaining the required functionality for optimal user experience, including quality acoustics. The team employed injection molding and overmolding technologies to help meet design targets as well as thermal analysis to ensure the overmolding would preserve the integrity of the internal electronics. Extensive materials research for the outside of the device addressed concerns about skin contact liabilities as well as general material properties. The solutions Synapse delivered provided Sol Republic a product that was ready for mass production.