Through Senior Design, I worked with 7 other team members to complete a year long design project for FieldLine Inc. FieldLine builds next generation magnetic sensors capable of reading brain activity using something called Magnetoencephalography or MEG. Our project for FieldLine was to research and develop a helmet/cap that will house 128 sensors around a patient's head. In addition, create a localization system that will find these sensors within a 1mm and 1° rotation tolerance. The significant challenges included: 
1. A non-metallic design (metal will interfere with the sensor readings)
2. Localize 128 sensors on various head shapes and sizes
3. A cap that can fit various head shapes and restrict sensor movement
Our design is currently being considered for a patent and so the design will remain confidential.
Design Process
I was the Manufacturing Engineer, in charge of researching and developing manufacturing methods, as well as prototyping and testing. Throughout the project, our team has developed ideas and generated prototypes to test their functionality and manufacturability. Two options that were heavily researched but NOT further developed are described below.
The team considered an exoskeleton design and ran a few tests for proof of concept. The design employed the notion of vacuum jamming, with a cap that included a network of connected tubes that filled the gaps between sensors. After testing it was shown that it lacked the retention force needed and had issues with conformity.
In the fall semester, the team developed a tensioning system to secure the sensors. The design included an ear-hub for ratcheting and a network of cables between the housings. We chose other options because of the complexity of the cabling, difficulty of repair and usability. 
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