ALEX—the Audio Listening EXperience—is a portable, all-in-one hearing-device demonstration system built around an anthropomorphic head, realistic ear canals and live listening for multiple participants.

The challenge was turning anatomical and acoustic requirements into a product that could travel, take regular handling and still be manufactured consistently. Electronics, microphones and interchangeable ear components all had to fit inside an organic form without losing control of fit, finish or performance.

My contribution covered advanced surface modelling, prototyping, DFM, lifecycle testing, material selection, electronics integration and supplier coordination. I refined the internal and external architecture through iterative prototypes, redesigned the in-house urethane-moulding process used for the anatomical ear components and supported overseas suppliers as the product moved toward manufacture.

ALEX launched in Q1 2026 and has since been sold internationally. The satisfying part was seeing a technically unusual idea make the full jump into a portable commercial product that could be built repeatedly—not just a one-off showpiece.