Hatch baby started by checking foam geometry by CNC’ing the foam to verify it had the best form to cradle a baby. After Studuiored prototyped that in-house and adjustments were made, the base was refined and checked for structural deformation under a 50lb weighted load.
A ribbed base was created which limited deformation to .7mm sag with the intent to glue the foam over the base hiding the wires between the sensors and the electronics and battery. Later, it was determined to overmold the foam onto the base and the entire rib structure was turned upside down to allow the wire to be placed from the bottom. New ID created both structural and ergonomic solution to improve the hand grip areas on both sides and ends.
Fully detailed CAD and parts drawings was released and production support of tooling methods were created for hiding foam flash into an invisible areas.