Case Study: Satellite Displays, Inc. achieves lightweight, on-the-go live-captioning badge production with Xometry injection molding

Satellite Displays Builds On-the-go Live Captioning Badge with Xometry Injection Molding

Satellite Displays, Inc. set out to solve communication barriers for deaf and hard-of-hearing people by creating Badger, a closed-caption smart badge that shows live speech-to-text and ID information. The engineering challenge was finding a manufacturing partner able to produce ultra-thin, durable housings (targeting 0.5 mm wall thickness and a final badge weight ≤2 oz) with small mating features. Satellite Displays turned to Xometry for high-resolution stereolithography prototyping and Xometry injection molding services to validate and manufacture the parts.

Xometry used its supplier network to source an injection molder that met the tight dimensional and finish requirements, produced SLA prototypes within a week, adapted tooling for a novel friction-pin closure, and delivered T1 samples and final ABS components (five connecting parts with SPL-A1 to SP-D3 finishes). By achieving the 0.5 mm walls, required fit/function metrics, and quick prototype-to-mold timeline, Xometry enabled Satellite Displays to launch Badger at scale—supporting live captioning in over 50 languages and advancing a product that can benefit some 455 million deaf and hard-of-hearing people worldwide.

Satellite Displays, Inc.

Lucas Taylor

Mechanical Engineer