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Cellairis | Universal Laptop Enclosure

The Brief

Create sleek and highly protective Chromebook cases for all laptop sizes

This content is the property of Cellairis Inc and any unauthorized distribution or publication is strictly prohibited. Cellairis Inc has provided explicit approval for showcasing this work as part of their trusted relationship with Analogy

Services

Focussed Market Research
Design Language
Concept Generation
Design Engineering
Product Architecture
Visualization
Prototyping
Production Support

Year

2017 – 2019

Client

Cellairis INC

Introducing

The universe laptop case

As we embarked on an industrial product development project, our focus was to create a laptop case that caters to the needs of K12 students. This meant designing something attractive to young users while ensuring comprehensive protection from everyday knocks and bumps.

Designed for a universal framework

The client’s vision was clear – a result-oriented linear process. That’s where our expertise in product design services was pivotal. We kick-started the journey with in-depth market research, dissecting product structures and pricing trends. This helped us spot opportunities to distinguish our design and establish a unique direction.

Competitor Snapshot
Understanding the market

Competitor Snapshot

The research brought to light some products that paralleled our goals. But we wanted more than just a mirror image. Our industrial design consultation process led us to delve deeper into their mechanics and materials. This intense analysis was instrumental in exploring alternative design paths, steering clear of existing market repetitions.

Industrial Design Process

Design Direction

A well-rounded understanding of the product, the market, and user challenges set the stage for a clear design direction. By applying the principles of professional industrial design services, we developed simple mechanisms that were easy to manufacture. Our aim was to achieve a minimalistic design that subtly conveyed functionality through color and material choices. We also factored in a modular product architecture for added versatility.

Our approach involved creating simple mechanisms that are easy to manufacture and offer universal solutions. We aimed for a clean, minimalistic design with a subtle touch of protection, using colors to indicate function and materials. Our design strategy also included a modular product architecture for greater versatility.
Design Direction
Industrial Design Process

Making Sense Of Data

In a project with a particular focus on K12 students, our client tasked us to create a laptop case that was both aesthetically appealing and robust enough to offer 360° protection. It needed to withstand daily wear and tear, a prerequisite in any item designed for this demographic.

Industrial Design Immersion

Ideation Concepts

Post-ideation not only facilitates idea iteration but also enhances project immersion. During this stage, we explore different solutions and variations for a given product and analyze its unique features.

Ideation Concepts
Detailing Core Concepts

Industrial Design Immersion

Detailing core concepts

Post-ideation not only facilitates idea iteration but also enhances project immersion. During this stage, we explore different solutions and variations for a given product and analyze its unique features.

Industrial Design Concept Development

Detailing core concepts

Having a clear vision of the concepts we wanted to pursue, we began organizing them through clear sketches that could effectively communicate the mechanisms, intentions, and unique features to both the client and engineering teams.

Detailing Core Concepts
Concept Development

Industrial Design Concept Development

Concept Development

We further developed the approach of fitting multiple laptops into a single enclosure. Each concept was meticulously crafted and presented through orthographic views, effectively communicating the material, manufacturing details, and the overall product design in achieving the goals set with the design direction.

Industrial Design Concept Development

Concept Development

We developed a range of scale and proportion concepts that define a cohesive design language and align with the broader user base. These concepts were refined through a detailed design and engineering cycle, ensuring that they met the primary requirements outlined in the design direction. The client was presented with a variety of options to choose from, providing them with the flexibility to select the most suitable design for their needs.

Concept Development
Building Core Features
Industrial Design Feature Development

Building Core Features

Once the client had selected a concept based on the pros and cons of each option, we focused on defining and detailing individual features before moving into the final engineering stage. Each feature required detailed attention to ensure that it fit and worked seamlessly with the other components of the concept. To facilitate this, we communicated these details through detailed sketches, ensuring that the design intent was clear to all stakeholders involved in the project.

Industrial Design Prototyping

Iterative Prototyping

We collaborated with our vendor partners to prototype the finalized concepts using various techniques, including cast urethane molds, CNC machining blocks of plastic and using transparent plastic to convey a sense of lightness. 

Our team created functional 3D models to test out scale, proportion, function, and fit rather than focusing solely on aesthetics. We also used co-molded details to enhance the product’s functionality and create a cohesive design.

Iterative Prototyping
Analysis & Refinement

Industrial Design Prototyping

Analysis & Refinement

The prototype and final concept underwent several discussions with the factory to refine details while maintaining design integrity. 

This phase was lengthy, as it involved balancing pricing with design updates and addressing material sourcing challenges to create a robust working prototype before mass manufacturing hundreds of thousands of units in a mold.

Industrial Design Techpacks

Techpack & Material Mapping

We initiated the process by collecting extensive data, then analyzing it to identify patterns and areas ripe for exploration. Leveraging CAD design services, we imported laptop models into our software, compiling them into a single file. This meticulous process helped us build a universal design language focusing on form, function, and familiarity, fostering seamless user interaction with the product.

Techpack & Material Mapping
Testing & Refinement

Industrial Design Prototyping

Testing & Refinement

To design a universal enclosure for 7-10 different laptop models, we had to take into account their varying dimensions, ports, and other functional details. We created a mapping of all these placements to determine where we could take liberties dimensionally and still maintain the design integrity of the product. 

To test this, we created mockups of each laptop model and overlaid them in CAD and paper models. This rigorous testing helped us identify the most efficient and practical design for a universal enclosure.

Universal Protection.

ULC Features

Universal Protection.

The task of creating a universal laptop case that could fit Chromebooks ranging from 11″ to 14″ was daunting, but we rose to the occasion and surpassed the brief without making any compromises. Our design not only provided industry-leading protection, but also included unique molding for corners that could withstand drops and cover a large area. Additionally, the corners flexed to accommodate different laptop sizes.

Our solution addressed the essential challenges of designing a universal laptop case and resulted in significant cost savings of over 135K USD in tooling. Furthermore, our design established a consistent product line language for all laptop enclosures across the product portfolio.

ULC Features

Corner Protection.

To create a stable mount with proper weight distribution, we made a few design modifications such as shifting the center of gravity and relocating the cable to the back of the product. This not only ensures that the cable doesn’t hinder any controls on the dashboard but also allows it to be routed through areas that are away from the main dashboard, providing a cleaner and more organized look.

Corner Protection.
Universal Fit

ULC Features

Universal Fit

By incorporating flexible corners into the design, we were able to achieve a versatile fit that accommodates different laptop profiles and edge details. Additionally, we implemented a closed hinge design that provides ample protection for the Chromebooks in the event of a fall. Our heat vents cover a large surface area, allowing for optimal heat dissipation, and the co-molding details ensure that the enclosure is both lightweight and thin while remaining protective.

To illustrate the internal workings of the enclosure, we used transparent material to showcase the flexible straps located inside. These straps, which are present in all four corners, enable the enclosure to accommodate various sizes of Chromebooks.

ULC Features

Heat Dissipation

To optimize heat dissipation for a variety of laptops, we thoroughly analyzed the placement of their heat vents on the back. 

We then designed a concave surface at an angle to accommodate these vents, allowing for better circulation of cold air to enter and hot air to be expelled. By reducing heat buildup on the flat surface, we were able to improve the overall cooling performance of the laptop.

How the Heat Dissipation happens in the universal laptop enclosure
Detail of the universal laptop enclosure

ULC Features

A Flexible Hinge

To ensure the protection of the laptop hinge in case of a drop, we opted for a strong TPU hinge with a serrated inner design. This unique design allowed for flexibility and protection, while also accommodating the 360º hinge feature found on most of the laptops we designed for. The TPU material provides durability and shock absorption while the serrated inner ensures a secure fit and protection.

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