Project spotlight: modular VersaSense sensor
From brainstorm to 3D prototypes. Mechanical engineer and project lead Aaron Lanneau explains.
VersaSense, a leading provider of enterprise IoT solutions, approached Artori for the redesign and development of their existing IoT sensor housing.
For this assignment, the client brought several requirements to the table:
- The IoT sensor housing needed to be plug & play and capable of housing up to three sensors
- The redesign had to be dustproof and waterproof, and ideally developed with ATEX certification in mind
- A higher battery capacity was required
- Use and maintenance needed to be as simple as possible
Our mechanical engineer and project lead Aaron guided the project from start to finish, with a recognisable and distinctive design as the foundation. Read on to discover why Aaron holds this project particularly close to his heart.
Project spotlight: modular VersaSense sensor
What makes this project special to you, and which challenges did you encounter?
It was a highly challenging and educational project, where I was able to work closely with both the client and my colleagues towards a strong end result — from brainstorming sessions to the realisation of 3D prototypes, including the necessary iterations and evaluations of the product and its functionality.
The main challenge lay in the complexity of the device: we had to integrate a large number of components into a very compact housing. After several brainstorming sessions and rough design concepts, we worked step by step towards a final composition, all the while keeping the manufacturability of the individual components in mind.
Is there a specific moment in the process you’re particularly proud of?
In October 2023, VersaSense wanted to present a prototype of the product at the ABISS trade fair at Kortrijk Xpo. This would be the first time our puzzle pieces and drawings would come to life. At this stage, we normally provide functional 3D prints, but for the product presentation we needed to convey the look and feel of the final product — which is why we opted for high-end prints.
It’s exciting — and quite unique — to get a glimpse of the final product so early in a project like this. The positive feedback and strong interest from trade fair visitors were the icing on the cake.
How did the collaboration unfold, both within your team and with the client and suppliers?
Within the team, we did a lot of brainstorming to ensure that the components were designed with production in mind from the very start. After each phase, we could also rely on well-founded and clear feedback from the client, which only improved the end result.
At a later stage of the project, we also aligned closely with suppliers to incorporate their feedback. This meant there were no surprises when ordering the parts, and we knew in advance that everything could be realised exactly as envisioned.
Which technologies were involved?
As with all our projects, we started with an intake meeting and documented the entire process in a Miro board. Alongside physical sketches and doodles, we developed the components in Siemens NX. The first prototypes are typically HP PA 3D prints — known for their high-quality finish and precision. For the trade fair prototypes, we used PolyJet technology. At the end of the project, we received the first production parts from the injection mould and carried out the final checks. After that, full-scale production could begin.
What are the key learnings for future projects?
This project undoubtedly contributed to the growth of my knowledge in the field of electronic housings (IP65, ATEX). Prototyping a new product is always engaging and educational — it clearly validates both the concept and the assembly of the components. At the same time, it almost always reveals small details that can still be optimised.
Prototyping allows us to develop a product in great depth. With this project, we were given that opportunity, and I’m very proud of the end result.
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