Slim Magnetic Button Enclosure Redesign (Flic)

Overview

Role and Ownership

As a freelance project, I redesigned the enclosure around existing Flic button internals to achieve the slimmest possible profile while maintaining usability and a premium “coin-like” aesthetic. This required reverse engineering the internal stack, building a multi-part housing architecture that could be assembled/disassembled with a dedicated tool, and controlling small-scale fits with tolerance-driven GD&T. The final prototypes preserved button function and LED visibility while adding magnetic attachment and a refined industrial design intent.

•	Reverse-engineered internal geometry and rebuilt packaging CAD around fixed electronics constraints
•	Designed a 3-part self-locking housing plus dedicated assembly/disassembly tool concept
•	Managed tight tolerance strategy and GD&T to ensure closure, alignment, and function at minimal thickness
•	Integrated LED light path and magnetic attachment while preserving device functionality
•	Worked with an Asia supplier and delivered three functional prototype iterations; handed off to client for sourcing

Approach 

 Requirements + CTQs: minimum thickness, premium look/feel, preserve function + LED visibility, serviceability
 Architecture tradeoffs: multi-part self-locking concept to meet thickness and assembly constraints
	CAD + tolerance strategy: controlled stack-up, latch engagement, and alignment features with GD&T
 Prototype iterations: fit/function tuning; assembly tool refinement; magnet and LED path checks
 Characterization / validation: verify actuation feel, retention/closure integrity, LED visibility, repeatability
 DFM + handoff: supplier-ready geometry intent and prototype learnings delivered to client for production sourcing

Results

•	Achieved a slim form factor (~8mm) while maintaining functionality
•	Enabled magnetic attachment and a premium “coin-like” industrial design intent
•	Delivered 3 functional prototype iterations and a production-feasible architecture for client handoff