To facilitate a clinical trial to test the efficacy of the wavelength and power of our light treatment, I built over 30 fully functioning prototypes. Each prototype included a flex PCB soldered and assembly by hand. The flex PCB was held in place by two plastic supports with magnetic mounts as I poured flexible polyurethane into a silicone mold.
Additionally, each prototype came with a charging base, also designed and assembled by me. The design of the prototype PCB included a Hall effect sensor that detected when the device was removed from the charging base and automatically turned the LEDs on. The charging base also included a USB-C receptacle and pogo pins mounted to another custom PCB.
The results of the clinical trial were exceedingly positive.