This project focuses on the engineering design, internal architecture, and mechanical development of a consumer-grade Percussive Therapy Massage Gun using SolidWorks. The development process balances external ergonomics with a complex electromechanical internal assembly, ensuring thermal efficiency, structural integrity, and manufacturing feasibility.

Role: Lead Mechanical Engineer & CAD Designer

Software Used: SolidWorks Premium 2024 (Part Modeling, Assembly, Motion Studies)

Key Focus Areas: Design for Manufacturing (DFM), complex mechanical linkage design, internal component packaging, and consumer electronics product styling.

Developing a robust handheld massager requires addressing several contradictory engineering requirements:

High Vibration & Stress: The housing must withstand continuous impact loads from the internal reciprocating mechanism without stress cracking.

Component Packaging: Fitting a high-torque brushless motor, eccentric drive linkage, control PCBs, and lithium-ion battery packs safely inside a compact, ergonomic handle.

Thermal Regulation: Providing adequate heat dissipation channels for the motor and electronics without compromising user safety or visual aesthetics.

The CAD engineering phase was divided into clear developmental stages, moving from conceptual forms to production-ready mechanical geometry.

The initial phase established a clean, lightweight, and balanced hand tool aesthetic.

Drafting & Shelling: Designed using sleek curvature transitions with appropriate draft angles to facilitate clean plastic injection molding extraction.

User Interface Integration: Integrated side-recessed control panel seating for power and speed switches, alongside a rear ventilation matrix designed for forced-convection cooling.

The internal cavity was engineered to securely mount and support high-frequency moving parts:

Reciprocating Kinematics: Modeled a precise Scotch-yoke or eccentric cam and connecting rod mechanism that converts the high-RPM rotational motion of the brushless DC motor into uniform linear percussion strokes.

Structural Ribbing & Alignment: Utilized a dual-shell structural system with robust internal boss mounts and reinforcement ribs to anchor the motor, main PCB, and modular battery pack.

The total assembly consists of tightly nested components engineered with interlocking tolerances. The core bill of materials covers:

Vibration Mitigation: Specially placed vibration isolators and internal dampers separate the drive mechanism from the outer housing to reduce hand fatigue for the end-user.

Interchangeable Head System: A standardized percussion head connector accommodates multiple therapy tips (ball, flat, bullet, and fork attachments) using secure friction-fit tolerances.

The finished solid-body models contain all details required for production toolmakers:

Bosses & Fasteners: Features explicit screw bosses aligned along the parting line for robust mechanical closure during final factory assembly.

Material Selection Targets: Optimized for high-impact ABS/PC blends for the main body shells and structural aluminum for the heat-generating mechanical linkages.

Delivered a complete, production-ready top-down assembly with zero part interferences.

Successfully resolved tight component space constraints while retaining an ergonomic, market-ready form factor.

Produced a definitive portfolio asset that proves professional competence in moving mechanisms, electronic packaging, and hardware product design.