RileyLink ToughCase by brandonarbiter

Last crawled date: 3 years ago

This is a case for the RileyLink. It includes three components:
Top of RileyLink Case - RileyLink_Case_-_Top_r10.STL (3D printed)
Bottom of RileyLink Case - RileyLink_Case_-_Bottom_r10.STL (3D printed)
Screw to fasten them together - Flat Head M2 X 0.4 mm pitch 6mm long (hardware)
Purchase:
This case is available on https://getrileylink.org/product/rltoughcase/ for $37 with an expected first ship date of June 1, 2017. The shipment will include both pieces of the ToughCase, the screw and the key ring.
Design goals:
3D printed clasps are fragile and break, resulting in cases that are held together with tape. We wanted to eliminate this outcome.
We created a connection point between the two 3D printed parts that allows a small screw to fasten them together.

We wanted to optimize for overall durability. Should a heavy object fall on my RileyLink (yes, this happened to me), we wanted it well protected.
We increased wall thickness to 2mm.
Instead of using a front/back 50:50 design like the original RileyLink case, we're using top/bottom 25:75 design. The increased substance of one piece (the bottom) yields a more sturdy structure.

If we shake the RileyLink case, we want the internals secure so they don't move around.
We gave each component of the RileyLink, the PCB and the battery, its own dedicated, specifically sized slot. It's intentionally a tight fit.

We wanted to keep the size of this case as close to the size of the original RileyLink case as possible.
See comparison pics below.

We wanted to align mini-USB port on the PCB to its opening on the case precisely, so inserting a mini-USB charger is easy.
We wanted to support physical add-ons like car keys or a Tile bluetooth locator.
We added a hole for a key ring.

Range:
We've had several inquiries about the range of the RileyLink inside a ToughCase, so we conducted a test.
SUMMARY:
- Test conducted on a golf course.
- Connection up to 30 meters (100 feet) was consistently successful. (3 of 3 successful)
- After 30 meters (100 feet), connection reliability began to degrade. (3 of 6 successful)
- Farthest range with successful connection demonstrated was 52 meters (171 feet).
EQUIPMENT:

(1) RileyLink in ToughCase (printed from Nylon)
(1) iPhone running LoopApp
(1) Medtronic 723 pump running VER 2.4A
(2) people
PROCEDURE:

The individual holding the RileyLink in ToughCase and iPhone stands still, while the individual holding the Pump moves away to a measured distance.

At each new distance:
1. On iPhone, run LoopApp > Settings > Rileylink > Tune
2. See if it succeeds or fails
3. Screenshot the Tune results (success or failure)
4. Measure the distance between the two people (using AtoB iPhone app in "as a crow flies" mode)
RESULTS:

Test Sequence 1
- 25 meters (82 feet) | 1 test | result: success
- 39 meters (128 feet) | 1 test | result: success
- 52 meters (171 feet) | 1 test | result: success (photos included below)

Test Sequence 2
- 28 meters (92 feet) | 2 tests | successful: 2, failing: 0
- 34 meters (112 feet) | 2 tests | successful: 1, failing: 1
- 42 meters (138 feet) | 2 tests | successful: 0, failing: 2
LIMITATIONS:

- We wanted to isolate this range analysis test from variables that may cause interference (e.g., walls, wireless devices, etc), so we conducted this test on a golf course.
- This test was conducted with one RileyLink in one ToughCase communicating with one pump. We did not attempt to replicate the results with multiple sets of hardware.
Instructions for Printing on Fictiv:
I had my case printed and shipped on fictiv.com with great results. My total cost was $79.49, including tax and shipping. It took five business days. (There's another option for 3 business days.)
Go to www.fictiv.com
Create your account
Select files: Upload .STL files
RileyLink_Case_-_Top_r10.STL
RileyLink_Case_-_Bottom_r10.STL

Process and Material
Process: 3D Printing
Material: Nylon

Color and Finish
Color: White or Black (might white one got dirty fast)
Finish: As printed

Production speed
3 days or 5 days (impacts price)

Price
Mine was about $30 per piece, +shipping, totaling $79.49.

Purchase the Screw:
Flat Head M2 X 0.4 mm pitch 6mm long You only need one. You can probably get it from your local hardware store, or here's a link to an Amazon 10-pack.
Optional Customization:
If you're comfortable with 3D modeling software, you can add your own custom fonts and graphics. Use the .IGS files. (The .STL are just for printing as is.)
As you'll see in the photos, I added orcas to the sides. I also added my name and phone number to the front (not pictured).
The 3D files posted on Thingiverse are generic. We left in the text on top that says "Medical Device", but the orcas and my contact info are gone.
Makers:
This case was a collaboration between Brandon Arbiter (T1D since 2011, OpenAPS since 2015, Loop since 2016) and Jason Lichtman, professional product design engineer Fictiv | LinkedIn.