Neroes EEG Headset

introduction

Neroes needed a wearable EEG headset that places its sensors correctly on almost any head, stays comfortable through a full training session and can be manufactured at a fraction of the cost of off-the-shelf alternatives. FullCycle took the device from concept to production-ready units in three months, covering ergonomics, sensor positioning, enclosure design, design for manufacturing and supply chain.

project context

Neroes develops a neurofeedback platform: an EEG headset reads brain activity and software turns it into a gamified training session for focus and stress regulation, used with professional athletes and corporate teams. The company already had a validated electronics and sensor system from its EEG partner, and software that worked with it. What it lacked was a device people could put on correctly without a technician. The off-the-shelf headsets it had been using were bulky, uncomfortable and hard to position, which limited how many users could be trained at once and kept the unit cost high.

problem
statement

EEG signal quality depends on sensor placement and stable skin contact, and both are hard to achieve across different head sizes without trained staff. The brief was to integrate the existing electronics into a headset that aligns its sensors automatically, keeps contact pressure low enough for long sessions, is durable and easy to clean between users, and looks like a piece of sports equipment instead of lab hardware. It also had to be manufacturable in low volumes at a cost that supported the client's business model.

project scope

  • Ergonomics
  • EEG headset cost
  • Intuitive sensor positioning
  • User experience

requirements

  • Portability
  • Durable and resistant
  • Minimalist design
  • High-end product
  • Futuristic design
  • Easy to clean
  • Easy to set up
  • Intuitive
  • Fast ear-bone fitting.

highlights

  • Idea to manufacturing in 3 months
  • 50 Complementary and competitor product analysed
  • 5 concepts generated
  • 20 different comfort systems tested
  • +60 3d printed parts for testing
  • 4 complete products manufactured
  • +100 files generated
  • 12 factories evaluated for manufacturing
  • Supply chain designed for plastics manufacturing, assembly and quality assurance
  • Certification support materials developed
  • Patent support materials developed

Sketches

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description
and
functioning

  • The headset has organic lines to blend with the head, designed for comfort and minimum footprint, as an enhancement to the human brain.
  • It has dampeners that ensure a strong sensor signal but with low pressure and discomfort
  • The material itself of the full headset acts as a spring that adjusts to the user’s head
  • The product is designed for disassembly, allowing for product updates and maintenance, and lower environmental impact and considering all parts are monomaterial, 100% recyclable
  • The back spring will allow the headset to be adjusted to the head and the design of the product itself automatically aligns the sensors
  • At the front a light rotation of a knob will enable the user to adjust the size of the headset for their head size in under 5 seconds
  • After taking the headset off the box, the user will turn on the device with a minimalist button on top of the headset and see the light turning yellow. By fitting the headset from the back to the front, the positioning becomes aligned, and whats needed is to turn the side sensors to touch the back of the ear. With this the user can immediately start using the game and training for mental ability enhancement

addressing requirements

The Neroes Headset was developed to meet the client's requirements for a portable, high-end, futuristic, minimalist, comfortable, and sports wearable related device. The headset is designed to be easy to set up, intuitive, easy to clean, resistant, durable, and has fast ear-bone fitting.

To meet the requirement for portability and minimalist design, the headset has organic lines to blend with the head while serving as an enhancement to the human brain. The headset has dampeners that ensure a strong sensor signal but with low pressure and discomfort. The material of the full headset acts as a spring that adjusts to the user's head. The headset has a back spring that allows the headset to be adjusted to the head, and the design automatically aligns the sensors.

To meet the requirement for a high-end and futuristic design, the headset is designed with a modern and sleek look that is relatable to sports wearables. It’s also durable, resistant, and easily cleaned and designed for disassembly, allowing for product updates and maintenance and lowering environmental impact, with all parts composed of monomaterial and 100% recyclable.

To meet the requirement for easy set-up and intuitive design, the headset has a minimalist button on top, and after taking it off the box the user can turn on the device and see the light turning yellow. By fitting the headset from the back to the front, the positioning becomes aligned, and the user can start using the game and training for mental ability enhancement immediately.

Overall, the Neroes Headset meets the client's requirements while also providing a comfortable and easy-to-use device for its users.

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renders

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results and
benefits

  • 2 patent applications filed by the client based on the design
  • Unit cost reduced roughly tenfold compared with the previous off-the-shelf headsets
  • Revenue from the new device from the first day after delivery
  • New market opened in Brazil

impact of
the project

Neroes replaced high-cost third-party headsets with its own device, cutting unit cost roughly ten times. Because the headset is quicker to fit, more users can be trained in parallel, which opened the door to larger clients and to a new market in Brazil.

conclusion

Three months from concept to production-ready units was possible because the critical subsystems (sensor dampening, sizing mechanism and enclosure) were prototyped and tested in parallel, with user feedback from the Neroes team at each iteration.

The headset is designed for disassembly, with monomaterial, recyclable parts, so it can be serviced and updated instead of replaced. Further versions are in development.

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