Reflecta
Reflecta was a concept for a portable AR smart mirror using a transparent display, depth-sensing cameras, and AR overlays to deliver virtual makeup try-ons and skin analysis in a compact, handheld device. The goal was to create a design that was ready for manufacture rather than staying at the concept stage.
The enclosure was modelled in CAD with injection moulding constraints integrated from the start, including:
Snap-fits and screw bosses for reliable, tool-free assembly.
Lip-and-groove joints for structural rigidity and clean external finishes.
PCB mounts, sensor cut-outs, and button placements designed with appropriate tolerances for ease of manufacture and consistent assembly.
Draft angles, parting lines, and uniform wall thicknesses to simplify tooling and minimise material use.
Focus groups were used throughout the project to inform decisions on ergonomics, usability, and aesthetics. Feedback on grip comfort, control placement, and portability guided iterative refinements, ensuring the final design addressed user needs as well as technical requirements.
The project concluded with fully dimensioned technical drawings, and a complete Bill of Materials (BOM) to prepare the design for manufacture. Finally, the enclosure was 3D printed to test ergonomics, assembly feasibility, and overall user interaction before moving toward production readiness.
This project developed skills in DFM principles, freeform modelling, user-centred design, mechanical-electrical integration, and prototyping, bridging the gap between concept and manufacturable product.
