01
Executive Summary
Project Vision
The Ion Wristband is a revolutionary voice-activated wearable device designed to seamlessly integrate with Helium AI, providing employees with hands-free access to AI-powered assistance. Combining the convenience of an event-style wristband with cutting-edge voice recognition technology, Ion transforms how users interact with AI in professional environments.
Key Innovation: Ion eliminates the need for traditional ID cards while providing instant AI access through a sleek, comfortable wearable that employees will be proud to wear daily.
Core Features
- Voice-activated AI prompts
- Dual connectivity (BT/WiFi)
- Haptic feedback system
Durability
- IP67 waterproof rating
- Weather-resistant design
- Flexible TPU construction
Customization
- Multiple color options
- Adjustable sizing
- Sleek, minimal aesthetic
02
System Architecture
Component Layout & Architecture
The Ion wristband features a highly integrated architecture built around the ESP32-S3 microcontroller, optimized for low-power voice processing and wireless connectivity.
Architecture Overview
Core Processing Unit
-
ESP32-S3-WROOM-1
Dual-core Xtensa LX7, 240MHz, 8MB PSRAM, 8MB Flash -
Power Management
Deep sleep <5µA, Active voice capture <10mA
Connectivity
-
Bluetooth 5.0 LE
Low-energy mode for phone pairing -
Wi-Fi 802.11 b/g/n
Direct cloud connectivity (2.4GHz)
Data Flow & Communication
Dual-Path Communication: Ion supports both Bluetooth (via smartphone) and direct Wi-Fi connectivity to Helium AI, providing flexibility and redundancy.
Communication Workflow
- Voice Capture: MEMS microphone captures audio via I2S interface (16kHz, 16-bit PCM)
- Local Processing: ESP32-S3 performs noise reduction and audio encoding
- Transmission: Audio data sent via Bluetooth LE or Wi-Fi to Helium AI
- Cloud Processing: Helium AI processes prompt and generates response
- Feedback: Vibration motor provides haptic confirmation
| Vibration Pattern | Count | Meaning | Duration |
|---|---|---|---|
| Single Pulse | 1x | Helium needs clarification | 200ms |
| Double Pulse | 2x | Task completed successfully | 200ms + 200ms |
| Rapid Burst | 5x | Error occurred | 100ms × 5 |
03
Core Components & Technologies
Audio Input System
MEMS Microphone
Model
SPW2430 / INMP441
Interface
I2S Digital
SNR
61 dB
Sensitivity
-26 dBFS
Frequency Response
100Hz - 10kHz
Optimized for voice capture with excellent noise rejection
Power System
Battery & Charging
Battery Type
LiPo 3.7V
Capacity
150-200mAh
Dimensions
25mm × 20mm × 2.5mm
Charging IC
MCP73831 / BQ24073
Charge Time
~1.5 hours
Battery Life
3-5 days typical use
Ultra-thin profile with integrated protection circuitry
Haptic Feedback
Vibration Motor
Type
Coin ERM Motor
Diameter
8-10mm
Height
2.5-3mm
Voltage
3.0V DC
Vibration Force
0.7g
Response Time
50-100ms
Reliable tactile feedback with programmable patterns
User Interface
Tactile Button
Type
Low-profile tactile switch
Actuation Force
160-200gf
Travel
0.25mm
Lifecycle
1M+ actuations
Waterproof
IP67 rated
Sealed design with positive tactile feedback
Waterproofing & Protection
Achieving IP67 waterproof rating requires a multi-layered approach combining enclosure design, conformal coating, and selective potting.
Conformal Coating
-
Silicone/Urethane
Thin protective layer on PCB -
Moisture Barrier
Prevents corrosion & shorts
Potting Compound
-
Epoxy/Silicone
Encases critical components -
Shock Absorption
Protects from impacts
Gaskets & Seals
-
O-Rings
Button & charging port seals -
Vent Membrane
Pressure equalization
Testing Required: IP67 certification requires submersion testing (1m depth, 30 minutes) and must be performed by certified testing facilities.
04
Design & Visual Mockups
Product Design Philosophy
Ion's design prioritizes comfort, discretion, and professional aesthetics. The wristband mimics the familiar form factor of event wristbands while integrating sophisticated technology seamlessly.
Design Principles
-
Minimalist Aesthetic
Clean lines, no visible screws or seams -
Ultra-Lightweight
Total weight under 15 grams -
Flexible Construction
Conforms to wrist movement naturally
-
Seamless Wraparound
No clips, hinges, or clasps -
Low Profile
Maximum thickness: 5mm -
Skin-Safe Materials
Hypoallergenic TPU silicone
User Interaction Flow
The interaction model is designed for simplicity and clarity, with distinct haptic feedback patterns for different states.
Interaction Sequence
- Press Button: User presses the tactile button to activate voice capture
- Speak Prompt: LED indicator (optional) shows recording status
- Transmit Data: Audio sent to Helium AI via Bluetooth or Wi-Fi
- Processing: Helium AI processes the request
- Feedback: Vibration pattern indicates status:
- 1 vibration = Helium needs more information
- 2 vibrations = Task completed successfully
- 5 vibrations = Error occurred
Color Variations
Ion is available in multiple professional colors to match corporate branding and personal preferences.
Professional Navy
Classic corporate color, suitable for formal environments
Vibrant Red
Bold and energetic, perfect for creative teams
Modern Gray
Neutral and versatile, matches any outfit
Fresh Green
Eco-friendly vibe, great for sustainability-focused companies
Classic Black
Timeless and professional, the default choice
Pure White
Clean and modern, ideal for healthcare and tech
05
Manufacturing & 3D Printing
3D Printing Materials & Techniques
The Ion wristband band is designed for 3D printing using flexible, waterproof materials that provide comfort and durability.
Recommended Materials
TPU (Thermoplastic Polyurethane)
Shore Hardness
85A - 95A
Tensile Strength
~9 MPa
Elongation at Break
250-280%
Print Temperature
220-235°C
Bed Temperature
40-60°C
- Excellent flexibility and durability
- Good chemical and abrasion resistance
- Compatible with FDM/FFF printers
Silicone Resin (Alternative)
Process
DLP/SLA
Biocompatibility
Medical-grade
Temperature Range
-40°C to 200°C
Water Resistance
Excellent
Post-Processing
UV curing required
- Superior skin compatibility
- Higher waterproof integrity
- Smooth, rubber-like finish
Recommendation: TPU is ideal for prototyping and low-volume production due to cost-effectiveness and wide printer compatibility. Silicone resin is recommended for premium, medical-grade wearables requiring maximum comfort and waterproofing.
Manufacturing Process
Production Workflow
Band Production
- 3D Print Band: Print flexible band using TPU filament
- Post-Processing: Remove support material, smooth surfaces
- Insert Electronics: Place PCB assembly into band cavity
- Seal & Pot: Apply conformal coating and potting compound
- Quality Check: Test waterproofing and functionality
Electronics Assembly
- PCB Fabrication: Order flexible PCB (2-layer, 0.2mm thick)
- Component Placement: SMD assembly of ESP32, sensors, etc.
- Reflow Soldering: Automated or manual soldering
- Programming: Flash firmware via USB-C
- Testing: Functional test of all components
Design Considerations
-
Wall Thickness: Minimum 1.5mm for structural integrity
Thinner walls may compromise waterproofing -
Cavity Design: Precise fit for PCB with 0.5mm tolerance
Allows for thermal expansion and component clearance -
Ventilation: Acoustic mesh for microphone, pressure vent
Maintains IP67 rating while allowing sound transmission -
Charging Port: Magnetic pogo pins or USB-C with gasket
Sealed design prevents water ingress during charging
Wraparound Mechanism
The seamless wraparound design eliminates traditional clasps and hinges, providing a clean aesthetic and improved comfort.
Design Options
Option 1: Snap-Fit Closure
-
Interlocking Tabs: Male/female connectors on band ends
Provides secure closure with audible click -
Adjustable Sizing: Multiple snap positions
Accommodates different wrist sizes (140-220mm)
Option 2: Elastic Stretch Band
-
Stretchable TPU: Band stretches to fit over hand
No closure mechanism needed -
Continuous Loop: Seamless design
Requires precise sizing (S/M/L options)
Recommendation: Snap-fit closure provides better adjustability and user experience. Elastic stretch bands require multiple size variants and may be difficult to put on/remove.
06
Helium AI Integration
API Integration Architecture
Ion connects to Helium AI through a dual-protocol architecture combining REST APIs for configuration and WebSocket for real-time voice streaming.
Communication Protocols
REST API (Configuration)
Protocol
HTTPS
Authentication
Bearer Token / OAuth 2.0
Data Format
JSON
Use Cases
Device registration, settings
- Device registration & pairing
- Configuration updates
- Firmware OTA updates
WebSocket (Real-Time)
Protocol
WSS (Secure WebSocket)
Audio Format
16kHz, 16-bit PCM
Encoding
Base64 (JSON payload)
Latency
<100ms
- Real-time audio streaming
- Bidirectional messaging
- Low-latency responses
API Endpoints & Data Flow
REST API Endpoints
| Endpoint | Method | Purpose | Authentication |
|---|---|---|---|
/api/v1/devices/register |
POST | Register new Ion device | API Key |
/api/v1/devices/{id}/config |
GET/PUT | Get/update device settings | Bearer Token |
/api/v1/auth/token |
POST | Obtain authentication token | Device Credentials |
/api/v1/firmware/latest |
GET | Check for firmware updates | Bearer Token |
WebSocket Message Format
// Client → Server (Audio Stream)
{
"type": "audio_stream",
"session_id": "session-uuid-123",
"audio": "base64_encoded_pcm_data",
"metadata": {
"timestamp": 1732694821000,
"sample_rate": 16000,
"channels": 1,
"bit_depth": 16
}
}
// Server → Client (Response)
{
"type": "response",
"session_id": "session-uuid-123",
"status": "completed",
"message": "Task completed successfully",
"vibration_pattern": "double_pulse",
"data": {
"result": "Your meeting has been scheduled"
}
}
Security & Authentication
Device Authentication
-
Unique Device ID: Hardware-based identifier
Stored in secure flash memory -
TLS 1.3: Encrypted communication
All data transmitted over secure channels -
Token Rotation: Automatic token refresh
Tokens expire after 24 hours
Data Privacy
-
No Local Storage: Audio not stored on device
Immediate transmission and deletion -
Anonymized Data: No PII in audio streams
Session IDs used for tracking -
GDPR Compliant: User data rights respected
Data deletion on request
Companion Mobile App
A companion mobile app (iOS/Android) provides device management, settings configuration, and acts as a Bluetooth bridge when Wi-Fi is unavailable.
App Features
- Bluetooth pairing & management
- Wi-Fi network configuration
- Battery status monitoring
- Vibration pattern customization
- Firmware update management
- Usage history & analytics
- Notification preferences
- Help & troubleshooting
- User profile management
07
Technical Specifications
Hardware Specifications
Microcontroller
ESP32-S3-WROOM-1
CPU
Dual-core Xtensa LX7 @ 240MHz
RAM
8MB PSRAM
Flash Storage
8MB
Microphone
I2S MEMS (SPW2430/INMP441)
Haptic Motor
Coin ERM (8-10mm)
Battery
150-200mAh LiPo 3.7V
Charging
USB-C / Magnetic Pogo Pins
Connectivity Specifications
Wi-Fi
802.11 b/g/n (2.4GHz)
Bluetooth
5.0 LE
Range (BT)
Up to 10m
Range (Wi-Fi)
Up to 50m (indoor)
Antenna
PCB integrated
Security
WPA2/WPA3, TLS 1.3
Protocols
HTTPS, WebSocket, MQTT
Physical Specifications
Dimensions
240mm × 25mm × 5mm
Weight
~15g
Band Material
TPU 90A / Silicone
Wrist Size
140-220mm (adjustable)
Waterproof Rating
IP67
Operating Temp
-10°C to 50°C
Storage Temp
-20°C to 60°C
Power Specifications
Battery Life
3-5 days (typical use)
Standby Time
7-10 days
Active Current
~10mA (voice capture)
Sleep Current
<5µA (deep sleep)
Charge Time
~1.5 hours (0-100%)
Charge Current
100-200mA
Input Voltage
5V DC (USB-C)
08
Bill of Materials (BOM)
Complete Component List
| Category | Component | Part Number / Spec | Qty | Est. Cost (USD) |
|---|---|---|---|---|
| Microcontroller | ESP32-S3-WROOM-1 | 8MB PSRAM, 8MB Flash | 1 | $3.50 |
| Audio | MEMS Microphone | SPW2430 / INMP441 | 1 | $1.20 |
| Haptics | Coin Vibration Motor | 8mm ERM, 3V | 1 | $0.80 |
| Power | LiPo Battery | 150-200mAh, 3.7V | 1 | $2.50 |
| Power | Charging IC | MCP73831 / BQ24073 | 1 | $0.60 |
| Interface | Tactile Button | Low-profile, IP67 | 1 | $0.40 |
| Interface | USB-C Connector | Waterproof, SMD | 1 | $0.50 |
| Passive | Resistors (assorted) | 0402/0603 SMD | 10 | $0.10 |
| Passive | Capacitors (assorted) | 0402/0603 SMD | 8 | $0.15 |
| PCB | Flexible PCB | 2-layer, 0.2mm, 50mm×20mm | 1 | $5.00 |
| Enclosure | TPU Band | 3D printed, 90A Shore | 1 | $3.00 |
| Protection | Conformal Coating | Silicone/Urethane | - | $0.50 |
| Protection | Potting Compound | Epoxy/Silicone | - | $0.80 |
| Sealing | Gaskets & O-rings | Silicone, various sizes | 3 | $0.30 |
| Assembly | Adhesives & Fasteners | Various | - | $0.50 |
| Total Component Cost (per unit): | $19.85 | |||
Cost Notes: Prices are estimates based on 2025 component costs for quantities of 100-1000 units. Bulk pricing (10,000+ units) can reduce per-unit cost by 30-40%. Additional costs include PCB assembly (~$5-8), testing (~$2), packaging (~$1), and shipping.
Cost Breakdown & Scaling
Prototype (1-10 units)
Components
$25-30
PCB Fabrication
$15-20
Assembly
$10-15
3D Printing
$5-8
Total per Unit
$55-73
Small Batch (100-1000)
Components
$20-22
PCB Fabrication
$8-10
Assembly
$5-8
Injection Molding
$3-5
Total per Unit
$36-45
Mass Production (10,000+)
Components
$12-15
PCB Fabrication
$3-5
Assembly
$2-3
Injection Molding
$1-2
Total per Unit
$18-25
09
Next Steps & Recommendations
Development Roadmap
Phase 1: Prototyping (Weeks 1-4)
- Order ESP32-S3 development board and components
- 3D print initial band prototypes in TPU
- Develop firmware for voice capture and transmission
- Test Helium AI API integration
Phase 2: Refinement (Weeks 5-8)
- Design custom flexible PCB
- Implement waterproofing and test IP67 rating
- Optimize power management for battery life
- Develop companion mobile app
Phase 3: Production (Weeks 9-12)
- Order small batch PCBs and components
- Set up injection molding for band production
- Conduct user testing and gather feedback
- Finalize design and prepare for mass production
Key Considerations
Regulatory Compliance: Ensure FCC/CE certification for wireless devices. Budget $5,000-10,000 for testing and certification.
IP67 Testing: Partner with certified testing lab for waterproof certification. Testing costs ~$2,000-3,000 per design iteration.
Battery Safety: LiPo batteries require UN38.3 certification for shipping. Include battery protection circuitry to prevent overcharge/discharge.
Recommended Suppliers
-
Electronics: Digi-Key, Mouser, LCSC
Reliable component sourcing with fast shipping -
PCB Fabrication: JLCPCB, PCBWay, OSH Park
Flexible PCB specialists with assembly services -
3D Printing: Shapeways, Xometry, Protolabs
TPU printing and injection molding services -
Batteries: Adafruit, SparkFun, Battery Space
Custom LiPo batteries with protection circuits