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.
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