POD
A SMART SLEEP SYSTEM
ABOUT
The Eight Sleep flagship product, the Pod, is a smart mattress system that optimizes and improves sleep through HRV and temperature modulation. Through proprietary data sensing and analytics, the Pod communicates with the accompany app to set and adjust the surface temperature of the mattress. The medium of thermal exchange occurs on the surface of the mattress, where the active grid absorbs or distributes heat depending on the user’s in-app settings.
PROCESS
INITIAL RESEARCH:
Prior to my start at Eight Sleep, the company had already released an initial product, the Eight Sleep Tracker. This Gen 1 product enabled sleep tracking and heating of the surface of the bed. However, through extensive user research, it was discovered that thermal regulation was still a big issue, especially cooling. As a result, the system needed to be completely redesigned as the sleep tracker technology could not support cooling. Research was done on different thermal transfer mediums and technology that supported it.
Initial Design Sketch
Worked alongside multiple engineers and designers to agree on an initial cosmetic design
Initial Prototyping
Using off the shelf components, an initial engineering mock-up was produced to validate design ideas and test for functionality
CONTINUED RSEARCH/ MATERIAL SELECTION:
To maximize the efficiency of the system, as well as reduce cost and noise output, several weeks were spent testing variations of components and manufactured parts. With the help from the China team, similar components from numerous suppliers were sent to the NY office for extensive testing with custom built test fixtures. As a result, an initial BOM list was successfully made.
Various heat sinks with similar designs from multiple manufacturers
INITIAL MANUFACTURING:
Through a combination of in-house and outsourced 3-D printing, custom sheet metal pieces, injection molded plastic, and existing manufactured parts, several initial cosmetic and engineering samples were built.
INITIAL TESTING:
To validate the design, the initial cosmetic prototypes were torn down to check for component compatibility and look for functional issues.
CONTINUED DESIGN:
In addition to the continued improvement of the Hub, the active grid component of the POD went through multiple material and design changes to match manufacturing constraints. Several components within the Hub were changed and designs were updated to prevent newfound issues in the initial prototype, such as leaks.
MANUFACTURING:
With the help of the China team and the manufacturers, the Eight Sleep Engineering Team was able to push through design verification test status into production verification test status, and eventually into mass production. Currently, more than 3000 units are sold and shipped throughout the USA.
CAD MODEL
Complete Cosmetic CAD Model
FINAL PRODUCT
Progression of prototype changes
FUTURE
With the successful launch of the flagship product, work began quickly on the third generation product. As it is proprietary data, I can only share the excitement for the amazing changes and I am looking forward to the next iteration in sleep fitness technology.