Wearable Technology Design and Development

Complete End-to-End Capability

Ignitec delivers wearable technology projects from early research through to certified, production-ready products. Our multidisciplinary team brings together hardware and electronics design, firmware and embedded systems, mechanical engineering, and industrial design to create compact, efficient, and fully integrated wearable devices.

Our process unites design and engineering from the start — reducing risk, improving performance, and ensuring that every wearable product we deliver is robust, efficient, and ready for manufacture.

Hardware and Electronics Design

Our electronics engineers develop complete hardware architectures optimised for wearable form factors. We focus on low-power design, compact PCB layouts, and advanced sensor integration, ensuring reliable operation and maximum runtime in small, sealed enclosures.

Core capabilities include:

• Multi-layer PCB and custom hardware development

• Advanced low-power and ultra-low-power design techniques

• Integration of IMU, ECG, EMG, GSR, HR, BP, RR, temperature, proximity, and environmental sensors

• RF and antenna design for BLE, Wi-Fi, Zigbee, NFC, GSM, and LoRa

• Power management, energy harvesting, and battery optimisation

• EMC-conscious layout and validation

Firmware and Embedded Software

Our embedded systems engineers develop firmware that delivers efficient, intelligent, and connected wearable devices. We specialise in low-level code that controls sensors, processes data, and communicates seamlessly with mobile or cloud systems.

We develop:

• Sensor fusion algorithms for motion and physiological signal processing

• Ultra-low-power firmware with advanced sleep and wake states

• Bluetooth 5.x, Wi-Fi, Zigbee, NFC, GSM, and LoRaWAN stacks

• Secure OTA firmware updates, diagnostics, and field support

• Modular, maintainable codebases using STM32, Nordic, and ESP32 platforms

Mechanical and Industrial Design

Our mechanical and industrial design teams ensure that each wearable product is both technically sound and user-focused. We design enclosures that balance ergonomics, comfort, and protection, ensuring the device performs reliably in its intended environment.

Our design process includes:

• 3D CAD design and mechanical integration

• Compact, lightweight, and user-friendly enclosure design

• IP-rated sealing, impact protection, and structural optimisation

• Material selection and design for manufacturability

• Custom enclosure development for medical, industrial, and consumer use

Prototyping and Validation

We maintain an in-house prototyping lab for rapid validation of wearable systems. This allows us to iterate quickly, optimise fit and function, and verify real-world performance before scaling to production.

Our prototyping process includes:

• Rapid prototyping using SLA, FDM, and Objet 3D printing

• Functional electronic and mechanical builds for evaluation

• Firmware integration and system bring-up

• Environmental and mechanical testing for durability

• Pre-compliance testing and design verification

Manufacturing Support

Ignitec provides complete manufacturing support for wearable technology. We prepare detailed build documentation, liaise with production partners, and oversee initial batch manufacture to ensure design intent and quality are maintained.

Support includes:

• Design for manufacture (DFM) reviews

• Supplier selection and liaison

• Pilot build and small-batch production

• Assembly QA and testing procedures

• Post-production engineering support

Integrated Delivery and Project Management

All projects are delivered through a structured, transparent process led by experienced project managers and supported by a cross-functional team. Using shared documentation and time-tracking systems, we maintain full traceability, communication, and control from concept through to delivery.

Our integrated approach ensures that design, engineering, and manufacturing flow seamlessly together — producing wearable systems that are not only technically advanced, but reliable, manufacturable, and built to perform.