A transparent log of how Orbit Fold moved from concept sketch to production‑tooled pilot. Eight phases, two years, five prototype generations.
Every decision in Orbit Fold was validated by a working prototype before being committed to tooling. We hold a small studio in Rotterdam for industrial design and a fabrication partner in Taipei for mechanical engineering — between them, a new prototype cycles every three weeks.
Twelve pages of marker sketches exploring folded geometries. The brief: a single object that could replace a power bank, a stand, and a desktop dock without compromise.
Three competing geometries modelled in Fusion 360 — a clamshell, a tri‑fold, and the chosen single‑fold continuous form. The continuous fold won on hand feel and structural simplicity.
Eight hinge mechanisms tested in 3D‑printed mockups: cam, friction disc, four‑bar, and torsion variants. The four‑bar steel mechanism was selected for its constant torque across the open range.
First aluminium prototype run. Charging tested at 15W continuous for 8 hours with thermocouples bonded to twelve points on the shell. Hotspot identified above the coil; resolved with a 0.4mm graphite spreader.
Spring rates evaluated from 0.8 N to 2.4 N. A 1.4 N spring with a viscous damper produced the most considered actuation feel. 30,000‑cycle life testing completed without measurable degradation.
Twenty units assembled to design verification spec for compliance testing, drop testing (1.5m onto wood), and a six‑week user study with eight people across three cities.
Refinements following the user study: a softened front lip radius, a quieter retraction damper, and a relocated LED moved from the top edge to the front face for ambient‑light visibility.
First production‑tooled units assembled. Final anodising vendor selected after three batches; 18 µm graphite anodise standardised. PVT lot complete; mass production scheduled for Q3 2026.
First full‑scale resin print. Validated proportions, hand feel, and folded volume against pocket and desk references.
First machined body with functional hinge. Used for the initial 200‑cycle hinge endurance run.
Fully integrated electronics, certified coil, production‑grade hinge. The basis for the DVT build.
“We replaced the front USB‑C bezel with a single chamfered cutout — saving 0.4 g and removing the last visible parting line on the front face. The body now reads as one piece from any angle above the desk.”