Brackets and mounts
Wearable Ankle Sensor Module (Exploded)
- Bounding box
- 527.5 × 60.0 × 18.0 mm
- Engine
- Precision B-rep
- Parameters
- 36
- Published
- August 7, 2026
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The prompt
Design a professional CAD model of an ergonomic wearable ankle-mounted sensor module for a smart gait and posture assistive device. The module should securely house a BNO055 IMU sensor, a small PCB, JST connector, status LED, and cable routing with strain relief. The enclosure should be compact (55 × 40 × 18 mm), lightweight (<40 g), with rounded edges, matte finish, and IP54 splash resistance. Use a two-piece enclosure consisting of a bottom housing and a snap-fit top cover with optional M2 screw holes. Design an adjustable 60 mm wide neoprene ankle strap with Velcro closure and breathable perforations. The sensor enclosure should attach using a slide-lock rail or quick-release clip and be positioned on the lateral side of the ankle above the ankle bone. Include soft silicone padding inside the enclosure for comfort and vibration isolation. The design should include internal PCB mounting bosses, cable guides, reinforcement ribs, cable exit with rubber grommet, and provisions for 3D printing in PETG or ABS. Generate an exploded assembly, isometric view, front, side, top, and cross-sectional views. The final product should resemble a premium medical wearable from Garmin, Fitbit, or Ottobock with a clean white and dark gray color scheme.
Parameters
| Name | Value | Range |
|---|---|---|
| Layout Gap | 80 mm | 50 – 150 |
| Housing Length | 55 mm | 40 – 100 |
| Housing Width | 40 mm | 25 – 80 |
| Housing Height | 18 mm | 10 – 30 |
| Wall Thickness | 2 mm | 1 – 4 |
| Fillet Radius | 2 mm | 0.5 – 4 |
| Boss Diameter | 4 mm | 2 – 8 |
| Boss Height | 4 mm | 2 – 10 |
| Rail Width | 8 mm | 4 – 15 |
| Rail Depth | 3 mm | 1 – 6 |
| Rail Height | 7 mm | 3 – 12 |
| Cover Length | 55 mm | 40 – 100 |
| Cover Width | 40 mm | 25 – 80 |
| Cover Thickness | 4 mm | 2 – 8 |
| Cover Fillet | 2 mm | 0.5 – 4 |
| Screw Hole Dia | 2.2 mm | 1.5 – 3 |
| Screw Offset | 5 mm | 2 – 10 |
| Clip Length | 25 mm | 10 – 40 |
| Clip Width | 15 mm | 10 – 25 |
| Clip Height | 8 mm | 4 – 15 |
| Strap Slot Width | 6 mm | 3 – 10 |
| Strap Slot Length | 8 mm | 5 – 15 |
| Strap Width | 60 mm | 20 – 80 |
| Strap Length | 300 mm | 100 – 500 |
| Strap Thickness | 2 mm | 1 – 4 |
| Perforation Dia | 4 mm | 2 – 8 |
| Perforation Spacing | 10 mm | 5 – 20 |
| Pad Length | 50 mm | 30 – 70 |
| Pad Width | 35 mm | 20 – 50 |
| Pad Thickness | 5 mm | 2 – 10 |
| Grommet Outer Dia | 10 mm | 6 – 15 |
| Grommet Inner Dia | 5 mm | 3 – 10 |
| Grommet Thickness | 4 mm | 2 – 8 |
| PCB Length | 40 mm | 20 – 60 |
| PCB Width | 30 mm | 15 – 45 |
| PCB Thickness | 1.6 mm | 1 – 3 |
Every value above is a live dimension. Open a model like this in the editor and each one becomes a slider you can drag before exporting.
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