Alloy’s primary responsibility on the project was development of the I/O and battery doors. Both doors needed to be as thin as possible, latch securely closed, yet easily open with a button release. Through extensive CAD architecture studies, tolerance studies and prototyping, Alloy helped drive the battery and connector locations in the camera as the door design developed. The battery door is sprung open for ease of access and the I/O door is detachable for accessory compatibility by utilizing a snap-on hinge. Alloy delivered production-ready designs for both doors, which were validated by a mechanically functional prototype of the camera.
One of the key challenges with the ultra-thin doors was fitting a one atmosphere seal within the thickness. Alloy designed both doors with over-molded radial seals that evolved through a series of analysis followed by quick-turn prototypes and then high-fidelity prototype testing. A cycle test fixture was designed and built by Alloy for opening and closing the doors thousands of times and then validating their water resistance.
Detachable Lens Cover
GoPro returned to Alloy to design a detachable lens cover mechanism that needed to be difficult to detach accidentally yet easy for the user to intentionally remove and replace. Additional constraints were minimal part count and tool-less operation. Alloy’s engineers developed and prototyped multiple concepts for the mechanism, ultimately settling on a simple, easily-tuned design that shipped with the camera. The pull-and-twist-to-remove design uses stainless steel wires to generate a spring force against cam surfaces that orient the rotation of the cover and bias it down against the camera body.