This project required solving both human and technical problems simultaneously. The original head cap design was causing skin damage and hair loss in elderly patients, while also failing to stabilize the sensors during lengthy surgeries — resulting in noisy, unreliable data.

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I redesigned the cap with a deep focus on skin-safe pressure distribution and sensor stabilization. I carefully selected materials for friction, stretch, and softness, and used compression layering to prevent migration without increasing pressure on fragile skin. Seam placement was a critical factor —

I ensured seams avoided high-friction or pressure-prone areas to prevent irritation or breakdown. I also modified the pattern to better distribute the weight of the electronics and maintain fit during extended wear.

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To ensure the cap would work for a variety of head shapes and sizes, I graded the pattern set and provided a repeatable construction method that emphasized comfort and consistent sensor alignment. These design changes resulted in a more stable, wearable, and ethically viable tool for collecting brain activity data during surgery.