Product Engineering, Design & Development Case Studies

Bright ideas for better sleep.

Unhealthy light exposure can quietly disrupt sleep, mood, and long-term wellbeing – and you wouldn’t even know it.

MiEye is a small wearable light sensor capable of recording and quantifying this invisible factor, enabling researchers to analyse correlations between light exposure and circadian rhythm that could help improve the quality of life for everyone.

Circadian Health Innovations, led by world-leading experts on the human circadian rhythm Sean Cain and Andrew Phillips, developed the device to a functional prototype level to validate the technology – but bringing MiEye to market required a transformation to get it manufacture-ready. Cobalt led this transition, addressing critical challenges in electronics design, durability, and everyday usability. In addition to the sensor module itself, Cobalt developed a USB-C powered charging cradle and three distinct attachment options for ways users can wear the sensor.

Through considered design and precise engineering, MiEye was optimised for real-world use and efficient production, making advanced light exposure research and insights more accessible than ever before.

MiEye cobalt work product2 1060x1060 2508

Focus Areas

Industrial Design
Design for Manufacture & Assembly
CAD Modelling
Electronics and Firmware
Packaging Design
Prototyping
Testing and Evaluation
Regulatory Compliance
Tooling Liaison and Management
Production Quality Control

Year

2024

Client

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MiEye cobalt work sidebyside2 1206x1542 2508

Design Outcomes

Hardware Redesign

Electronics Redesign

Durability

Wearability Options

Charging and Battery

Transfer to Production

Cobalt re-engineered the hardware for mass production, while preserving the sensor’s core functionality. An injection-moulded lens was developed to provide a non-directional light filter, ensuring accurate readings from any orientation and upgraded Bluetooth LE communication was integrated for data transfer.

Cobalt reviewed the electronics and redesigned the system for improved performance and manufacturability, selecting more appropriate components, developing a new PCBA, carrying out prototyping and testing to validate functionality. The storage was also configured to capture and store 5-6 months worth of data.

MiEye’s housing design was refined to achieve a high IP67 dust and water resistance rating, drop, impact (100kg crush resistance) and vibration resistance. Validated through rigorous testing, this robust approach ensures the device can reliably capture light data in everyday, body-worn use.

One key project requirement was ensuring the product is comfortable for extended use for a variety of users and scenarios. Three interchangeable attachments – under clothing magnetic lanyard, outside clothing lanyard and spring clip cradle - give users flexibility in how they wear the sensor.

A compact USB-C charging cradle was designed for quick, secure docking. Power optimisation was key to getting the most out of the small battery, so the electronics were designed for ultra low power consumption – allowing users to get up to 3-4 days of continuous logging.

After several rounds of prototypes for user and verification testing, Cobalt guided CHI through every step of the transfer to manufacture – identifying suitable contract manufacturers, overseeing the tooling and sampling phase, and managing the first production run.