Product Overview

Case: The customer for this project develops advanced technologies for defense, aerospace, space, materials, and environmental applications. One such technology enables a transparent substrate to transition from nearly clear to tinted in less than two seconds. The system uses a patented dual-polymer electrochromic coating combined with a proprietary voltage-control algorithm. Tri-Power Design was engaged to package this technology into a consumer sunglasses product that automatically adjusts tint based on ambient light conditions.

Solution: The project followed a complete product development cycle that combined industrial design, prototyping, electrical engineering, mechanical engineering, and design for manufacturing. Ultimately, the effort resulted in injection-molded production parts. The final product is a stylish pair of sunglasses designed for both active outdoor use and casual urban environments.

Industrial Design and Prototyping Constraints

Design Challenges: A primary design constraint involved the coated substrate, which could bend in only one direction. As a result, the material limited how the lenses could contour to the user’s face. To address this, Tri-Power Design engineers collaborated closely with industrial designers through multiple prototype iterations. The team refined the shape through repeated evaluation and validation using in-house 3D printing.

Engineering and Manufacturing Optimization

From a manufacturing perspective, the challenge centered on modeling the sunglasses and all related components while preserving design intent. At the same time, the design needed to support cost-effective, high-volume production. Tri-Power Design engineers applied advanced CAD modeling techniques and leveraged extensive experience in injection molding to resolve these challenges and deliver a manufacturable product.

Call 973.227.8214 or email us today to learn more about the Consumer Sunglasses.