Noah Cordle logo markCase Study · Industrial Design

EV

A wearable system for cycling that combines safety, audio, biometrics, and everyday carry into one object. Open-ear bone-conduction earbuds with a built-in heart-rate sensor and a MagSafe case that doubles as a wallet.

RoleIndustrial Designer
ToolsSolidWorks · KeyShot · Procreate
Year2024
StatusConcept
EV earbuds and MagSafe case, hero render
01 · Overview

Overview.

EV is a wearable system designed to improve the cycling experience across safety, entertainment, and health tracking. The earbuds use bone conduction so riders can hear audio without blocking the road. A sensor at the temple reads heart rate passively, and the case doubles as a wallet.

The goal was simple. Reduce the number of things a rider has to carry while improving how each one works.

02 · Brief

Brief.

The brief was to design a pair of wireless earbuds for a brand that does not typically make audio products. The product needed to feel like it belonged to that brand, not just an existing earbud with a logo added.

I chose Trek Bicycle. Cycling already creates a tradeoff between awareness, audio, and gear. This product fits naturally into that space.

03 · Research

Research.

Cycling introduces a real safety problem when it comes to audio. Riders want music, but losing awareness of the environment can lead to accidents.

20%of bike accidents in Japan between 2012 and 2020 were linked to auditory distraction.
devices a rider often carries: phone, heart-rate monitor, and wallet.
Openear audio is one of the only ways to keep awareness while listening.
Research board, pocket clutter, heart-rate access, awareness while biking
Research board. Overlapping problems of safety, biometrics, and pocket clutter.
Research board 2, 20% auditory distraction stat, heart rate via temporal artery, open earbud form factor, MagSafe card holder
Key product moves. Open-ear audio, a temple-based sensor, and a case that absorbs the wallet.
04 · Opportunity

Opportunity.

Most riders already build their own setup. Separate earbuds, a chest strap, a phone mount, and a wallet. The problem is not missing products. It is too many of them.

TodayMultiple devices. Multiple tradeoffs.

Sealed earbuds block sound. Chest straps feel restrictive. Wallets and phones sit in different places.

EVOne system.

Open-ear audio keeps awareness. A temple sensor replaces the chest strap. The case holds cards and attaches to the phone.

05 · Language

Language.

The form takes direct inspiration from Trek’s existing products. The goal was to make it feel like a natural extension of their design language.

06 · Ideation

Ideation.

I started by pulling specific elements from Trek products and translating them into earbud forms. Each concept tested how far those references could go without breaking usability.

The final direction combined the helmet arc, circular driver, and a natural placement for the heart-rate sensor.

Ideation sketches, Trek design language applied to earbud form
Sketch sheet. Each concept tied to a specific Trek reference.
07 · Form

Form.

The final form wraps around the ear with a continuous arc that sits naturally against the head. The structure keeps the ear open while maintaining a stable fit during movement.

The geometry balances comfort, stability, and brand identity.

08 · Materials

Materials.

Each material was chosen for a specific role. Nothing is decorative.

Aluminum provides structure.
Titanium sits against the skin for the sensor.
Rubber adds grip and comfort.
Fabric covers the display to reduce visual noise.

Exploded view, labeled components
09 · Sensor

Sensor.

Wrist-based heart-rate tracking can become unreliable during intense activity. Movement and sweat affect the reading.

The temporal artery sits close to the skin and aligns naturally with the ear hook. Placing the sensor here allows passive tracking without extra effort from the user.

Heart-rate sensor position against the temporal artery
Sensor placement. The pad rests against the temple during normal wear.
10 · Display

Display.

The display is hidden behind a fabric surface. When off, it disappears. When active, it shows through the material.

This keeps the product visually clean while still giving feedback when needed.

Cloth-covered digital display and power button
Display detail. Fabric surface with embedded status readout.
11 · Case

Case.

The case combines charging and everyday carry. It attaches to the back of the phone using MagSafe and holds two cards.

This removes the need for a separate wallet and keeps everything in one place.

MagSafe-compatible charging case doubling as a cardholder
Case detail. Charging dock and integrated cardholder.
12 · App

App.

The companion app brings all ride data into one place. Heart rate, distance, and activity history are tracked over time.

The interface stays simple and readable outdoors, with minimal color used for key actions.

Trek Workout companion app, home, workouts, nav bar
App interface. Workout tracking and daily overview.
13 · Reflection

Reflection.

This project was about simplifying a system. Instead of adding features, I focused on replacing what riders already carry.

The biggest takeaway was learning how to design around integration. Every part of the product had to earn its place by removing something else.