Popcase Air
for iPhone
Popsockets LLC
Role: Lead Product Design Engineer
Timeline: 3 months from initial concept to first round of tooled parts
Problem
With dozens of brands flooding the market with similar products, Popsockets set out to offer a superior, differentiated product. Our goal was to create a sleeker way to position a popsocket grip into a case, by integrating the two to increase pocketability, utilize the swappable top, and allow for wireless charging.
Solution
A truly unique case with features to solve device pocketability, grip swappability, and drop protection while maintaining a slim feel with a unique pop-out grip design and blow-molded air pocket sidewalls.
Unique Protection
Enhanced Functionality
Air-pockets, in your pockets.
First ever phone case with
air-pocket technology
The PopSocket, upgraded. With new
pocket-friendly
pop-out mechanism
1 iPhone 2 Blow-molded airbags 3 TPU bumper 4 TPU "accordion" 5 PC back 6 PC "platform" 7 PopSocket
Pop-Out Base
Inspired by the double popping action of our accordion
Customers love the fidget-ability aspect that we tried to carry over into the case design in order to solve for one of the main complaints about our grips - snagging on pockets
Brainstorming
Prototyping
Overmolded over-center hinge
Case CAD
An extra pop to maintain finger space and comfort
Blow-Molded Protection
Inspiration
Blow-Molding Process
Tooled Parts
Challenges Met
Balancing Functionality
The usability features we needed to solve for were all fighting against each other and there were trade-offs. We had to consider the user experience and create proper spacing as needed with the real estate we had on the back of the case.
Air Pockets
Blow-molding was a new process for me and it is something that is not typically done on such a small scale. It was difficult to get the pockets small enough to fit within the wall of the case and shut off on with the overmolded TPU.
Extra Pop
The pop-out base was the perfect solution for this use case but took a great deal of work to tune and design the living hinge. I referenced the accordion on our standard grip and optimized it for the small space it had to live in. By tweaking the durometer with the tooled parts I was able to achieve the right amount of force in relation to the accordion.
Skills Demonstrated
Prototyping
Concept iteration
CAD (SolidWorks)
Living hinge design
Project ownership
Thinking outside the box