Abstract: Compound structures and methods for forming the same are described. The compound structures can be used to form an enclosure. The enclosure may be formed from metal, such as aluminum, and further include one or more non-metal regions that allow for transmission and receipt of electromagnetic waves, such as radio frequency waves. The non-metal region can include a first section, a second section, and an optional cosmetic section. The first section can be firmly molded onto a metal section of the enclosure by small pores formed within the metal section. The second section can engage with interlock features of the first section. The optional cosmetic section can cover the first section and the second section such that the first section and the second section are not visible from an exterior of the enclosure.

Abstract: A micro speaker assembly including a speaker enclosure having an enclosure wall separating a surrounding environment from an encased space, wherein the enclosure wall defines, in part, an acoustic channel that acoustically couples the encased space to the surrounding environment, and the enclosure wall comprises a chemically etched insert molded metal portion that is mechanically interlocked and hermetically sealed to a plastic portion. The micro speaker further including a speaker assembly positioned within the encased space, the speaker assembly having a sound radiating surface facing the metal portion of the enclosure wall, a voice coil extending from the sound radiating surface, a magnet assembly having a magnetic gap aligned with the voice coil, and an acoustic chamber formed, in part, by the metal portion of the enclosure wall and the sound radiating surface.

Abstract: An enclosure and a method for forming an enclosure are disclosed. The enclosure may be formed from metal, such as aluminum, and further include a non-metal portion allowing for transmission and receipt of electromagnetic waves. The non-metal portion may be interlocked to the enclosure and in particular, to a region within the enclosure including a first material having a relatively high strength and stiffness compared to the non-metal portion. Interlocking means may include forming dovetail cuts into the enclosure to receive the non-metal portion, a hole or cavity drilled into the enclosure which includes internal threads, and a rod inserted into the first material to provide a tension to the non-metal portion. Methods of assembling internal components using anodization are also disclosed.

Abstract: Manufacturing methods that combine molding processes and shaping processes are described. The systems and methods described can be used to form composite parts using a single manufacturing process. In some embodiments, the methods involve positioning a workpiece within a mold cavity, then injecting a moldable material within the cavity at pressures sufficient to deform the workpiece such that features, such as protrusions or cavities, are formed within the workpiece. The resultant composite part includes the workpiece molded to a molded material. In some embodiments, the workpiece is a layer of metal material and the molded material is a structurally rigid plastic material, such that the composite part is a structurally rigid plastic with a metal coating. In some embodiments, multiple workpieces are molded within a composite part.

Abstract: Compound structures and methods for forming the same are described. The compound structures can be used to form an enclosure. The enclosure may be formed from metal, such as aluminum, and further include one or more non-metal regions that allow for transmission and receipt of electromagnetic waves, such as radio frequency waves. The non-metal region can include a first section, a second section, and an optional cosmetic section. The first section can be firmly molded onto a metal section of the enclosure by small pores formed within the metal section. The second section can engage with interlock features of the first section. The optional cosmetic section can cover the first section and the second section such that the first section and the second section are not visible from an exterior of the enclosure.

Abstract: Attachment systems for attaching a wearable electronic device to a user including a sizing band and a retaining band are disclosed. The sizing band includes at least one sizing eyelet and a band-insertable end. The retaining band includes at least a post for insertion into the sizing eyelet of the sizing band and a concealment aperture configured to receive the band-insertable end of the sizing band. On a bottom surface of the retaining band can be a recessed guide bed configured to guide the band-insertable end along the bottom surface of the retaining band. A wearable electronic device can couple to both the sizing band and the retaining band by accepting an end portion of each band into receiving channels extending into opposite sidewalls of the housing.

Abstract: Compound structures and methods for forming the same are described. The compound structures can be used to form an enclosure. The enclosure may be formed from metal, such as aluminum, and further include one or more non-metal regions that allow for transmission and receipt of electromagnetic waves, such as radio frequency waves. The non-metal region can include a first section, a second section, and an optional cosmetic section. The first section can be firmly molded onto a metal section of the enclosure by small pores formed within the metal section. The second section can engage with interlock features of the first section. The optional cosmetic section can cover the first section and the second section such that the first section and the second section are not visible from an exterior of the enclosure.

Abstract: Attachment systems for attaching a wearable electronic device to a user including a sizing band and a retaining band are disclosed. The sizing band includes at least one sizing eyelet and a band-insertable end. The retaining band includes at least a post for insertion into the sizing eyelet of the sizing band and a concealment aperture configured to receive the band-insertable end of the sizing band. A bottom surface of the retaining band can be a recessed guide bed configured to guide the band-insertable end along the bottom surface of the retaining band. A wearable electronic device can couple to both the sizing band and the retaining band by accepting an end portion of each band into receiving channels extending into opposite sidewalls of the housing.

Abstract: An electronic device having an enclosure with a sealing element to prevent ingress of contaminants at an interface between sealing element and a material is disclosed. The material may include an injection molded material that forms at least part of a radio frequency transparent window. The enclosure may include a first channel that receives the material. A second channel may open to the first channel and receive the sealing element. The sealing element may initially extend at least partially into the first channel. However, the material may provide compression forces to the sealing element to compress the sealing element out of the first channel, or at least compress the sealing element further into the second channel. The sealing element may provide a counterforce against the material to increase or enhance a seal against ingress attempting to pass through the enclosure at the interface between sealing element and the material.

Abstract: An enclosure and a method for forming an enclosure are disclosed. The enclosure may be formed from metal, such as aluminum, and further include a non-metal portion allowing for transmission and receipt of electromagnetic waves. The non-metal portion may be interlocked to the enclosure and in particular, to a region within the enclosure including a first material having a relatively high strength and stiffness compared to the non-metal portion. Interlocking means may include forming dovetail cuts into the enclosure to receive the non-metal portion, a hole or cavity drilled into the enclosure which includes internal threads, and a rod inserted into the first material to provide a tension to the non-metal portion. Methods of assembling internal components using anodization are also disclosed.

Abstract: A composite material is disclosed which includes a plastic layer formed on a layer of metal. The metal layer includes pores into which an adhesive is introduced. The plastic layer is injection molded onto the metal layer so as to contact the adhesive in the pores. The plastic layer is thus bonded to the metal layer.

Abstract: An enclosure and a method for forming an enclosure are disclosed. The enclosure may be formed from metal, such as aluminum, and further include a non-metal portion allowing for transmission and receipt of electromagnetic waves. The non-metal portion may be interlocked to the enclosure and in particular, to a region within the enclosure including a first material having a relatively high strength and stiffness compared to the non-metal portion. Interlocking means may include forming dovetail cuts into the enclosure to receive the non-metal portion, a hole or cavity drilled into the enclosure which includes internal threads, and a rod inserted into the first material to provide a tension to the non-metal portion. Methods of assembling internal components using anodization are also disclosed.

Abstract: An electronic device having an enclosure with a sealing element to prevent ingress of contaminants at an interface between sealing element and a material is disclosed. The material may include an injection molded material that forms at least part of a radio frequency transparent window. The enclosure may include a first channel that receives the material. A second channel may open to the first channel and receive the sealing element. The sealing element may initially extend at least partially into the first channel. However, the material may provide compression forces to the sealing element to compress the sealing element out of the first channel, or at least compress the sealing element further into the second channel. The sealing element may provide a counterforce against the material to increase or enhance a seal against ingress attempting to pass through the enclosure at the interface between sealing element and the material.

Abstract: Manufacturing methods that combine molding processes and shaping processes are described. The systems and methods described can be used to form composite parts using a single manufacturing process. In some embodiments, the methods involve positioning a workpiece within a mold cavity, then injecting a moldable material within the cavity at pressures sufficient to deform the workpiece such that features, such as protrusions or cavities, are formed within the workpiece. The resultant composite part includes the workpiece molded to a molded material. In some embodiments, the workpiece is a layer of metal material and the molded material is a structurally rigid plastic material, such that the composite part is a structurally rigid plastic with a metal coating. In some embodiments, multiple workpieces are molded within a composite part.

Abstract: Methods and systems for manufacturing composite parts that include anodizable portions and non-anodizable portions such that an interface between the anodizable portions and non-anodizable portions are free of visible defects are described. The non-anodizable portions can be made of anodizable metals such as aluminum or aluminum alloy. The non-anodizable portions are made of material that do not generally form an anodic film, such as plastic, ceramic or glass materials. In particular, the methods described relate to manufacturing methods that are compatible with anodizing processes and avoid defects related to anodizing processes. In particular embodiments, the methods involve avoiding trapping of anodizing chemicals within a gap between an anodizable portion and a non-anodizable portion, which prevents the anodizing chemicals from disrupting the uptake of dye in a post-anodizing dyeing process.

Abstract: Compound structures and methods for forming the same are described. The compound structures can be used to form an enclosure. The enclosure may be formed from metal, such as aluminum, and further include one or more non-metal regions that allow for transmission and receipt of electromagnetic waves, such as radio frequency waves. The non-metal region can include a first section, a second section, and an optional cosmetic section. The first section can be firmly molded onto a metal section of the enclosure by small pores formed within the metal section. The second section can engage with interlock features of the first section. The optional cosmetic section can cover the first section and the second section such that the first section and the second section are not visible from an exterior of the enclosure.

Abstract: Cable structures with localized foam strain reliefs and systems and methods for making the same are provided. In some embodiments, at least one localized foam strain relief may be incorporated into or positioned underneath a cover of a cable structure. For example, the ratio of base material to foam material may be varied during the manufacture of the cover, such that distinct portions of the cover may include more foam than other portions of the cover. This may provide localized strain relief properties to the cable structure while also obviating the need for additional strain relief components to be provided adjacent to or over specific portions of the cover.

Abstract: Systems and methods of providing a composite material that is bendable but substantially resists stretching under tension. One embodiment may take the form of a composite material formed by over-molding a woven glass fiber with silicone. The woven glass fiber may be rolled out with a silicon polymer melted into the woven fabric as the rolling process continues. The composite of the two materials may provide a material that bends easily but does not substantially stretch.

Abstract: Methods and systems for manufacturing composite parts that include anodizable portions and non-anodizable portions such that an interface between the anodizable portions and non-anodizable portions are free of visible defects are described. The non-anodizable portions can be made of anodizable metals such as aluminum or aluminum alloy. The non-anodizable portions are made of material that do not generally form an anodic film, such as plastic, ceramic or glass materials. In particular, the methods described relate to manufacturing methods that are compatible with anodizing processes and avoid defects related to anodizing processes. In particular embodiments, the methods involve avoiding trapping of anodizing chemicals within a gap between an anodizable portion and a non-anodizable portion, which prevents the anodizing chemicals from disrupting the uptake of dye in a post-anodizing dyeing process.

Abstract: An enclosure and a method for forming an enclosure are disclosed. The enclosure may be formed from metal, such as aluminum, and further include a non-metal portion allowing for transmission and receipt of electromagnetic waves. The non-metal portion may be interlocked to the enclosure and in particular, to a region within the enclosure including a first material having a relatively high strength and stiffness compared to the non-metal portion. Interlocking means may include forming dovetail cuts into the enclosure to receive the non-metal portion, a hole or cavity drilled into the enclosure which includes internal threads, and a rod inserted into the first material to provide a tension to the non-metal portion. Methods of assembling internal components using anodization are also disclosed.