Objective

A client was interested in creating an application demo of their LED impregnated fabric technology. The demo would consist of a custom LED control module, which would create a unique light pattern for each article of fabric. The fabric and controller would be incorporated into running apparel, allowing tracking of runners during an event via identification of the light patterns in event video feeds. The control module needed to be small, unobtrusive to the user, waterproof, and battery powered with a use duration of at least 6 hours. The event chosen required that units be available within 8 weeks.

Approach

The design was based around the ATmega32U4 microprocessor, along with an integrated Li-Po battery and charging circuitry. A single IP67 rated USB-C connector was used for charging and programming of the microprocessor, along with control of the LED fabric while in use. An over-molded elastomer exterior allowed use of a dome tactile power switch, and a custom waterproof light pipe allowed for power and status LEDs to be incorporated into the enclosure.

Result

One round of prototyping was performed, with demo-ready units available within 6 weeks. The product was successfully demoed at the 2018 NYC marathon.