An electronic slider switch was designed for the SnakeFan® product.
The design was completed in Mathematica® that included a model for the
nonlinear snap-through of the switch. The design replaced a prepackaged
design that was previously designed into other products. The slider switch
design included an extensive design and analysis of the switch to balance
a variety of constraints including: human factor analysis for the allowable
force for turning on and off, stress relaxation of the nickel plated phosphor
bronze material used in the switch, material yield limits, and the required
electrical contact force for ensuring good contact. The preliminary work
leading to the final design involved the rapid development of twelve conceptual
designs for the switch. The final design and sizing was arrived at by detailed
analytical stress analysis and balancing design for assembly
and design for manufacturability concepts.