The First Fitbit: Engineering And Industrial Design Lessons

August 9, 2024 by Maya Posch 7 Comments

It could happen to anyone of us: suddenly you got this inkling of an idea for a product that you think might just be pretty useful or even cool. Some of us then go on to develop a prototype and manage to get enough seed funding to begin the long and arduous journey to turn a sloppy prototype into a sleek, mass-produced product. This is basically the story of how the Fitbit came to be, with a pretty in-depth article by [Tekla S. Perry] in IEEE Spectrum covering the development process and the countless lessons learned along the way.

Of note was that this idea for an accelerometer-based activity tracker was not new in 2006, as a range of products already existed, from 1960s mechanical pedometers to 1990s medical sensors and the shoe-based Nike+ step tracker that used Apple’s iPod with a receiver. Where this idea for the Fitbit was new was that it’d target a wide audience with a small, convenient (and affordable) device. That also set them up for a major nightmare as the two inventors were plunged into the wonderfully terrifying world of industrial design and hardware development.

One thing that helped a lot was outsourcing what they could to skilled people and having solid seed funding. This left just many hardware decisions to make it as small as possible, as well as waterproof and low-power. The use of the ANT protocol instead of Bluetooth saved a lot of battery, but meant a base station was needed to connect to a PC. Making things waterproof required ultrasonic welding, but lack of antenna testing meant that a closed case had a massively reduced signal strength until a foam shim added some space. The external reset pin on the Fitbit for the base station had a low voltage on it all the time, which led to corrosion issues, and so on.

While much of this was standard development and testing fun, the real challenge was in interpreting the data from the accelerometer. After all, what does a footstep look like to an accelerometer, and when is it just a pothole while travelling by car? Developing a good algorithm here took gathering a lot of real-world data using prototype hardware, which needed tweaking when later Fitbits moved from being clipped-on to being worn on the wrist. These days Fitbit is hardly the only game in town for fitness trackers, but you can definitely blame them for laying much of the groundwork for the countless options today.

pulse oximeter as a small sticker that sticks on your fingernail and measures heart rate, motion, and blood oxygen

This Fingernail Sticker Can Detect When You Stop Breathing

January 1, 2023 by Orlando Hoilett 8 Comments

Sometimes we dig through the archives to see what kind of crazy hacks we can pull out of the depths of the world wide web and this one was worth sharing. Researchers at Northwestern University developed a sticker that’s applied to the fingernail and measures heart rate, motion, and blood oxygen, all without a battery.

The photoplethysmograph (PPG) system is similar to what we’ve covered before and the motion sensor is simply an accelerometer, so we won’t go over those aspects of the device. The parts of the device that did catch our attention were the battery-less operation as well as its size. It’s just so dang small! And fits snuggly on a fingernail or on even on your earlobe. The size here is actually a very interesting feature and not just a marketing plug. Because the device is so small and lightweight, it is very easy to adhere to the fingernail or skin with very little sensory perception. Basically, the person wearing the device won’t even notice it’s there. That’s definitely an advantage over the traditional, bulky, hospital-grade instruments we’ve grown accustomed to.

The device adheres really well given its small and lightweight design, so motion artifacts are significantly reduced. Motion artifacts in PPG-based devices are due to the relative motion between the optode (LED and photodiode) and the skin. The traditional approaches of ensuring the device don’t move are for the patient to keep very still during a recording, to wear the device tightly against the skin (think of how tightly you need to wear your smartwatch to get consistent readings), or use some seriously tough and uncomfortable adhesive as you may have done if you’ve ever gotten an electrocardiogram reading before. This device eliminates those three problems.

The other aspect of the device that caught our attention is its use of wireless power instead of a battery. In some senses, this could be seen as an advantage or as a disadvantage. The device relies on NFC for power and data transmission, a pretty common approach for devices that only need to be used intermittently. Wireless power could be a bit problematic for continuous monitoring devices which provide readings every second or several times a second. But who knows, wireless power seems to be everywhere these days.

Digging into the details a bit, the double-layer antenna is designed around the circumference of the device using wet etching to create traces on a copper polyimide foil. The team electroplated holes through the different layers of the device (optode layer, first antenna layer, polyimide, second antenna layer, component layer, protective top coat) connecting the antenna to the die pad NFC chip (SL13A, AMS AG). Connecting the chip requires some pretty fine-pitch soldering techniques, but nothing we’re not accustomed to here at Hackaday. Overall, they seemed pretty successful, obtaining a Q factor of 16 and a transmission distance of 30 mm using a smartphone and not some giant reader antenna.

Definitely, a really cool project that we recommend checking out.

Custom-designed photoplethysmogram designed to fit in ear like an ear bud

Breathe Through Your Ears?

December 4, 2022 by Orlando Hoilett 15 Comments

With all the attention given to heart rate monitoring and step counting, respiratory rate monitoring is often overlooked. Smartwatches are starting to incorporate respiratory rate monitoring more and more these days. However, current devices often simply look at breaths per minute without extracting more interesting features of the respiratory waveform which could give us more insight into our bodies than breaths per minute could alone. [Davies] and his team decided they wanted to change that by making an earbud that can measure respiratory rate. Continue reading “Breathe Through Your Ears?” →

Infant is wearing sensor vest as she is held by her mom. ECG, respiration, and accelerometry data is also showing.

Open Source Wearables For Infants

August 9, 2022 by Orlando Hoilett 8 Comments

We’ve seen plenty of hacks that analyze biometric signals as measures of athletic performance, but maybe not as many hacks that are trying to study behavior. Well, that’s exactly what developmental psychologists at Indiana University and the University of East Anglia have done with their open-source, wireless vest for measuring autonomic function in infants.

Their device includes a number of components we’ve seen already. There is an HC-05 Bluetooth module, AD8232 electrocardiography (ECG) analog front-end, LIS3DH 3-axis accelerometer, MCP73831 LiPo charger, a force-sensitive resistor for measuring respiration, and a Teensy microcontroller. Given how sensitive an infant’s skin can be, they opted for fabric electrodes for the ECG instead of those awful sticky ones that we’re accustomed to. They then interfaced the conductive fabric with copper plates using snap fasteners (or press studs or snap buttons, whichever terminology you’re more familiar with). The copper plates were connected to the circuit board using standard electrical wire. Then, they embedded the sensors into a vest they sewed together themselves. It’s basically a tiny weighted vest for infants but it seems well-padded enough to be somewhat comfortable.

They did a short test analyzing heart and breathing rates during a period of “sustained attention,” basically when you’re quietly fixated on a single object or activity for a period of a few minutes or longer. They were really pleased with the vest’s ability to collect consistent data and noted that heart and respiratory rate variability decreased during the sustained activity test, which was an expected outcome. Apparently, when you’re pretty fixated on a singular task, your body naturally calms down, so to speak, and the variability in some of your physiological responses decreases. Well, unless someone slowly walks up behind you and pinches you, of course.

They provided detailed instructions for recreating the vest, so be sure to check those out. They probably want their device to look a lot less than body armor though. Maybe the Sewbo can help them out with their next iteration.

Hackaday Links: March 6, 2022

March 6, 2022 by Dan Maloney 12 Comments

As if the war in Ukraine weren’t bad enough right here on Earth, it threatens knock-on effects that could be felt as far away as Mars. One victim of the deteriorating relationships between nations is the next phase of the ExoMars project, a joint ESA-Roscosmos mission that includes the Rosalind Franklin rover. The long-delayed mission was most recently set for launch in October 2022, but the ESA says that hitting the narrow launch window is now “very unlikely.” That’s a shame, since the orbital dynamics of Earth and Mars will mean that it’ll be 2024 before another Hohmann Transfer window opens. There are also going to be repercussions throughout the launch industry due to Russia pulling the Soyuz launch team out of the ESA’s spaceport in Guiana. And things have to be mighty tense aboard the ISS right about now, since the station requires periodic orbital boosting with Russian Progress rockets.

Continue reading “Hackaday Links: March 6, 2022” →

E4 Empatica device for measuring location, temperature, skin conductance, sleep, etc. on arm

Choosing The Optimal Sampling Rate For Your DIY Heart Rate Monitor

September 3, 2020 by Orlando Hoilett 19 Comments

With wearables still trying to solidify themselves in the consumer health space, there are a number of factors to consider to improve the reliability of such devices in monitoring biometrics. One of the most critical such parameters is the sampling rate. By careful selection of this figure, developers can minimize errors in the measurement, preserve power, and reduce costs spent on data storage. For this reason, [Brinnae Bent] and [Dr. Jessilyn Dunn] wanted to determine the optimal sampling rate for wrist-worn optical heart rate monitors. We’ve shared their earlier paper on analyzing the accuracy of consumer health devices, so they’ve done a lot of work in this space.

The results of their paper probably don’t surprise anyone. The lower the sampling rate, the lower the accuracy of the measurement, and the higher the sampling rate the more accurate the measurement when compared to the gold standard electrocardiogram. They also found that metrics such as root mean square of successive differences (RMSSD), used for calculating heart rate variability, requires sampling rates greater than 64 Hz, the nominal sampling rate of the wearable they were investigating and of other similar devices. That might suggest why your wearable is a bit iffy when monitoring your sleeping habits. They even released the source code for their heart rate variability analysis, so there’s a nice afternoon read if you were looking for one.

What really stood out to us about their work is how they thoroughly backed up their claims with data. Something crowdfunding campaigns could really learn from.

Reliability Check: Consumer And Research-Grade Wrist-Worn Heart Rate Monitors

April 7, 2020 by Orlando Hoilett 12 Comments

Wearables are ubiquitous in today’s society. Such devices have evolved in their capabilities from step counters to devices that measure calories burnt, sleep, and heart rate. It’s pretty common to meet people using a wearable or two to track their fitness goals. However, a big question remains unanswered. How accurate are these wearable devices? Researchers from the Big Ideas Lab evaluated a group of wearables to assess their accuracy in measuring heart rate.

Unlike other studies with similar intentions, the Big Ideas Lab specifically wanted to address whether skin color had an effect on the accuracy of the heart rate measurements, and an FDA-cleared Bittium Faros 180 electrocardiogram was used as the benchmark. Overall, the researchers found that there was no difference in accuracy across skin tones, meaning that the same wearable will measure heart rate on a darker skin-toned individual the same as it would on a lighter skin-toned. Phew!

However, that may be the only good news for those wanting to use their wearable to accurately monitor their heart rate. The researchers found the overall accuracy of the devices relative to ECG was a bit variable with average errors of 7.2 beats per minute (BPM) in the consumer-grade wearables and 13.9 BPM in the research-grade wearables at rest. During activity, errors in the consumer-grade wearables climbed to an average of 10.2 BPM and 15.9 in the research-grade wearables. It’s interesting to see that the research-grade devices actually performed worse than the consumer devices.

And there’s a silver lining if you’re an Apple user. The Apple Watch performed consistently better than all other devices with mean errors between 4-5 BPM during rest and during activity, unless you’re breathing deeply, which threw the Apple for a loop.

So, it seems as if wrist-worn heart rate monitors still have some work to do where accuracy is concerned. Although skin tone isn’t a worry, they all become less accurate when the subject is moving around.

If you’d like to try your own hand with fitness trackers, have a look at this completely open project, or go for the gold standard with a wearable DIY ECG.