Product Design
Behind-the-ear form factor with interchangeable ear hooks. CAD designs complete in Fusion360.
Standalone AI Earpiece with LTE
Fully standalone audio, biometric, and visual interface—no phone required. Built-in LTE cellular, camera, 6 sensor types. All AI processing on your Guardian Server.
Behind-the-ear form factor with interchangeable ear hooks. CAD designs complete in Fusion360.
Component-level costing at 10-50K unit volumes
| Category | Component | Part / Spec | Cost Low | Cost High |
|---|---|---|---|---|
| Processing | MCU | ESP32-S3-MINI-1-N8 | $3.00 | $5.00 |
| Connectivity | LTE Module | Nordic nRF9160 (10x16x1mm) | $12.00 | $18.00 |
| Nano SIM Slot | Push-push nano SIM | $0.50 | $1.00 | |
| LTE Antenna | Ceramic chip antenna | $1.50 | $3.00 | |
| Biometric | PPG/SpO2 | MAX30102 | $2.50 | $4.00 |
| IR Temperature | MLX90615 | $3.00 | $4.00 | |
| GSR AFE | AD5940 (3.6x4.2x0.6mm) | $8.00 | $12.00 | |
| GSR Electrodes | Gold-plated balls (2x) | $1.00 | $2.00 | |
| IMU | MPU6050 | $1.50 | $2.00 | |
| Environmental | Gas/Env Sensor | BME688 | $5.00 | $8.00 |
| Camera | Camera Module | OV2640 compact (8x8x5.5mm) | $12.00 | $18.00 |
| Audio | MEMS Microphone (×2) | SPH0645LM4H | $3.00 | $5.00 |
| Amplifier | MAX98357A | $1.50 | $2.00 | |
| Speaker | 8mm micro driver | $1.00 | $2.00 | |
| Bone Conduction | Adafruit 1674 (21.5x14.5x7.9mm) | $4.00 | $6.00 | |
| Power | Battery | 300-400mAh LiPo | $3.00 | $4.00 |
| PMIC | BQ25120A | $1.00 | $1.50 | |
| Mechanical | PCB | 4-layer flex-rigid (expanded) | $5.00 | $7.00 |
| Housing | Medical-grade polymer | $4.00 | $6.00 | |
| Ear Hook | Silicone + wire | $1.00 | $2.00 | |
| Misc Hardware | Connectors, seals | $1.00 | $1.50 | |
| Assembly | Assembly & Test | Contract mfg + LTE cert | $4.00 | $6.00 |
| TOTAL UNIT COST | $78.50 | $120.00 | ||
Target Retail: $249
Gross Margin: 52% - 68%
Standalone LTE: No phone required
Charging Case: $12-18 cost
Core operates fully standalone via LTE—no phone required. All AI processing occurs on your Guardian Server via encrypted tunnel. When away from home WiFi, Core connects directly to Guardian Server over cellular.
