Case 1: Luggage Tracker Case

Customer Requirements (Week 1)

Our client approached us to develop a luggage tracker case: a compact square box with a tracker inside, which could be opened later to replace the tracker.

• Keep it as small and lightweight as possible to maintain aesthetics, reduce weight, and control costs;
• Ensure it stays securely closed during movement without accidental opening.

Challenge:

• Designing a secure opening/closing mechanism without making the overall size too large;
• Balancing functionality with aesthetics and cost.

Solutions (Week 2)

We proposed two options:

1. Latch mechanism – secure but would make the case much bulkier.
2. Magnetic closure – using high-strength, small-form magnets to keep the two parts attached, requiring only a minor size increase.

The client chose the magnetic closure. Thanks to our long-term partnership with magnet suppliers, we could source and test different grades within days, speeding up validation.

Iterations (Week 3 – 6)

First round: We produced sketches and a 3D-printed prototype. Functionality was fine, but the client didn’t like the visible magnets. (Week 3)

Revision: We hid the magnets in the base; the lid magnets remained exposed due to structural limits, which the client accepted. (Week 4)

Second round: We sent an updated prototype. The aesthetics improved, but magnetic force was insufficient. (Week 5)

Further optimization: We upgraded from 2000-gauss magnets to high-grade N56 magnets, achieving a major boost in holding power. (Week 6)

Over the course of about a month — including shipping time, testing and holidays — we moved from sketches to multiple prototypes and refinements.

Our Edge & Result

On paper this product looked simple, but our edge came from:

• Four rounds of rapid prototyping (each in about a week);
• Long-standing relationships with suppliers and finishing partners, ensuring fast turnaround and reliable quality;
• Competitive pricing compared to peers at the same quality level.

The final sample achieved the perfect balance between aesthetics and holding power. After client approval, we proceeded to mass production smoothly.