This project was a new correctional facility phone developed at Guardian Telecom. I worked on ingress protection (IP) testing and choosing the right durometer for the elastomer parts so the phone could hold up to rough use. The official IP testing was done at a certified facility, but I was involved in planning the tests, going over the results, and making design changes based on what we learned. I also helped build the CAD models while keeping sheet metal DFM rules in mind so the design would be easier to manufacture. Along the way, I worked with electrical and quality teams to make sure the phone was durable, comfortable to use, and resistant to damage. 

Skills: SolidWorks, IP Testing, Sheet Metal, DFM, 2D Mechanical Drawings, Vendor Management, DFMA, Cross-Functional Collaboration, Product Development Lifecycle  

The exploded views show both the front and back of the phone, breaking out the housing, keypad, circuit board, and armored cord. These visuals helped me and my team plan ingress testing, spot potential water entry points, and make sure fasteners and seals were easy to reach during assembly. Laying out the hardware and board stack this way also helped us confirm the design would stay serviceable and repeatable for production. 

After the first prototype arrived from vendors in China, the phone was mounted on a test jig to simulate water spray from different angles. The testing was prepared to meet IPX5/IPX6 standards, which replicate heavy rain and water jet conditions. Official certification testing was completed at a certified facility, where water-tracing paste was applied inside the housing to identify points of ingress. This revealed leakage around certain fasteners, gaskets, and seams, leading to design changes that improved the phone’s sealing and durability. 

The phone was mounted on a motorized jig that rotated it in all directions while being exposed to IPX5 spray testing, simulating heavy rain conditions with pressurized water jets. The video shows the phone during testing, with water directed at all sides to check for ingress. After the test, the housing and handset were inspected for leaks, and water-tracing paste inside revealed any entry points. These results gave clear feedback on gasket performance, sealing quality, and hardware placement, guiding design improvements for stronger water resistance in future builds.