Securing computational design data through 4D scanner

Developing wearables with the optimal fit and comfort remains a difficult yet crucial challenge. Not only do these factors make the device feel more seamless to use, but they are directly tied to maximising overall performance and sensor accuracy. However, the fact that each person’s anatomy is completely unique presents a major hurdle. But what if there was a way to meticulously engineer comfort, fit and sensing so precisely, it could deliver the optimal experience for nearly everyone?

Samsung’s solution is Computational Design. This multidimensional process harnesses AI and advanced computing to analyse hundreds of thousands of quantitative and qualitative data points to generate, test, and refine product designs with greater precision. The result is a fundamental shift from subjective feedback to objective, data-driven engineering, creating superior products with the optimal fit for the widest range of users.

That description captures computational design in the abstract—like a dictionary definition. To understand how computational design is actually used to create superior wearables, Samsung Newsroom visited the Samsung Design Innovation Center (SDIC) in San Francisco, home to the Computational Design Lab.

Federico Casalegno, EVP and Head of the Samsung Design Innovation Center

Spearheading the SDIC is Federico Casalegno, Executive Vice President and Head of the Samsung Design Innovation Center, who has spent the past two decades mastering the practice of computational design and leading the implementation of this core concept into Samsung’s product development. We sat down with Federico to discuss how SDIC employs computational design as a primary tool to create and optimise experiences for Samsung’s wearables, particularly the Galaxy Buds4 Series.

1. Tell us about SDIC’s role.

At SDIC, our mission is to deliver meaningful experiences by understanding people and their evolving lifestyles—always in the context of human-centered design. Ultimately, we want to delight customers and create products that help people live happier, healthier, more creative, and more productive lives, while building a better future for all and preserving the environment. To achieve this, SDIC brings together the power of design and creativity with data-driven decision-making. Supported by AI, machine learning, robotics, and advanced computing, our talented, multidisciplinary team of designers is constantly pushing the boundaries of what’s possible, delivering unparalleled user experiences and real, tangible benefits.

At SDIC, design is combined with AI, data, and computing to achieve maximum comfort for wearable devices.

2. What exactly is computational design, and what is the philosophy behind it?

While we live in a unique era of technological innovation, Samsung’s approach to design was always deeply human-centered as we believe that technology without humanity is merely perfection without purpose. Computational design is how we bring this philosophy to life—it is the process of harnessing the immense power of AI, data, and computing to design products for people, rather than expecting people to adapt to our products. This approach helps us to create devices that are fundamentally functional, intuitive, comfortable and beautifully crafted. Today, this methodology is applied all across our wearable portfolio, including Galaxy Watch8 and Galaxy Buds4 Series.

The computational design process involves various state-of-the-art testing equipment, including 4D scanning.

3. How does computational design turn the ‘fit’ of a device into an objective, measurable metric?

For developing something as personal as a wearable that remains in contact with you for extended periods, fit is an essential element. It’s not just about comfort though; a secure fit is also needed for maximising the precision of the device’s sensors. However, traditional design methods fail to measure wearability objectively, as they only rely on a small sample of people for product testing.

Computational design fundamentally changes this. By leveraging massive, digitalised datasets and advanced AI simulations, it transforms wearability into a quantifiable metric that allows Samsung to measure comfort and fit like never before. By being able to consider all the unique shapes and curves of the human ear or the wrist through computational design, our designers are equipped with trustworthy, objective insights that are difficult to attain through traditional methods.

Optimal design parameters are derived through AI and physics-based simulations, which are then cross-verified with robot testing.

4. Tell us in detail how the computational design process works in the lab, and how it was implemented in the Buds4 series.

Our computational design process relies on three elements: real people, digital twins, and robots. We capture 3D and 4D scans of a diverse global audience, integrating precise anatomical data to create ‘digital twins.’ We then run AI and physics-based simulations, cross-validating the results with physical robot testing.

For the Buds4 series, we applied this exact process to achieve perfect wearing comfort and premium sound. We analysed hundreds of millions of global ear data points and ran more than 10,000 simulations to perfect the new blade design. This objective data led us to subtly reduce the size of the main head^[1] and refine the angle of rotation—minor adjustments that resulted in a dramatic, universally validated increase in stability and comfort.

5. How does Samsung’s computational design ultimately benefit the users?

Samsung’s computational design process is powered by a unique proprietary dataset built exclusively from within Samsung, and our team has developed several specialised AI programs based on this data. This combination gives us unique insights while we constantly innovate our design processes and methods. For Galaxy Buds and Watch specifically, this translates into improved wearing comfort, stability and sensor accuracy—key factors that elevate both the user experience and product performance.

Samsung’s lineup of wearables, such as Galaxy Buds4, Galaxy Watch8, and Galaxy Ring, all incorporate computational design in its development process.

6. Looking ahead, how do you see Computational Design evolving over the next decade?

Computational design is now a foundational element of Samsung’s development process across all our wearable products. Our goal remains to maximise wearability, fit, comfort and sensor performance to ultimately serve the people using it.

Looking ahead, the true power of this process is its continuous evolution. As our dataset continues to grow, custom AI tools will drive more accurate simulations and deeper insights. These advancements will not only further improve product wearability, but also unlock exponential innovations down the line that lead to an entirely new category of wearables that can redefine the boundaries of user experience. Ultimately, this symbiotic partnership between computational design and AI frees our designers to be more creative, empowering us to deliver measurably superior products and experiences for the people who use them.

_{^[1] Galaxy Buds4 only}

When Jacob Kiplimo storms past the finish line, he’s not just running on talent — he’s running on data. The Ugandan long-distance star and Team Galaxy athlete trains with Galaxy Watch8, which turns complex biometric data into valuable insights that shape his winning strategy.

This powerful combination of technology and talent has already reaped rewards. After securing a dominant win at the 2025 Chicago Marathon and shattering the half-marathon world record this March in Lisbon, the 25-year-old is now targeting success at the 2026 London Marathon.

Samsung Newsroom asked him to detail his data-driven training regime which embodies this year’s World Health Day slogan, “Together for health. Stand with science.”

With exclusive access to his Samsung Health metrics, we take an inside look into his gruelling training programme which has seen him cover over 100km in just one week. Discover how insights led him to adjust his training for optimal recovery and how even a “rest day” can include a 3km run.

Screenshots from Jacob Kiplimo’s Samsung Health app show his varied training routine, including light jogs and long-distance runs

Q. Congratulations on your recent world record at the 2026 Lisbon Half Marathon. What’s the secret to your success?

There’s no secret. It’s just about discipline. You have to work hard, be extremely focused, and manage your energy — knowing when to rest and when to push harder. But honestly, the most important part is that you have to really want what you’re working toward. I wouldn’t have broken the world record if I didn’t follow that formula.

Q. You finished second at the 2025 London Marathon and are now preparing to go one step further at this year’s event. What role has your Galaxy Watch8 played in your training?

My coach doesn’t live in Uganda, so my Galaxy Watch8 has basically become his personal assistant here. Even though he’s not with me, he can get real-time analysis and reports on my running form through the Running Analysis feature in Samsung Health. We track my heart rate and pay close attention to my pace for each kilometre. During the harder sessions, I also monitor the asymmetry readings to see if I’m overcompensating on one side so I can avoid strain. Contact time is another key aspect I keep an eye on, making small adjustments to my form to ensure every stride is as efficient as possible. I always try to improve my running economy, so these insights are incredibly helpful.

Q. Looking at your recent Samsung Health data, we can see some clear patterns in your training routine. Tell us about your regime.

Consistency is key, but athletes must not be obsessed with training. What many people don’t realise is that rest is equally as important as physical training. To compete at your best, you need to be able to maximise your energy, and the only way to do that is through consistent rest. But “rest” doesn’t always mean no training. A rest day can mean running 3km instead of 40km. You have to be consistent in what you’re doing, but you also need to listen to your body and know when to slow down. Technology can help a lot with this.

Jacob Kiplimo’s Samsung Health data from March 13–19 reveals how he ramps up his training routine throughout the week  

Q. Can you give us an example of how a specific insight from the Samsung Health app led you to adapt your training programme?

The decision to run 3km instead of 40km that I just mentioned was a true story. After experiencing some lingering soreness during a recent 24km run, I decided to turn what was intended to be a 40km run into a light 3km jog to ensure I could recover and have the stamina to get through 40km another day. The Samsung Health app was very helpful for me here. It kept me informed so I could allow my body to fully recover and prevent a potential injury or burnout.

Q. We’ve seen how a professional runner like yourself uses data to reach their goals. What advice would you give to someone who is just starting their running journey, and how can the Running Coach feature get them on the right track?

For beginners, it is very important to ease into things and be patient. You will build up stamina over time; it’s about knowing when to push yourself and when to stop. Not everyone has a personal coach with them to tailor a training plan. But the Running Coach feature provides customised programmes to help even beginners train for a marathon. It tells you exactly what you should be doing during a run, motivates you, and helps you improve. New runners are fortunate to have this fantastic technology which can guide them every step of the way. It’s also great for more experienced runners looking to take on a full marathon as it provides structured training programmes.

Q. On World Health Day, the message is “Together for health, stand with science.” How does this relate to your own philosophy?

Science helps me throughout my training. I don’t know where I would be without the ability to track data on my Galaxy Watch8. I use that science to shape my daily routine. Science and technology help me to perform at my best, and I believe it can do the same for anyone.

From a young runner in Uganda to a world-record holder, Jacob Kiplimo proves what happens when relentless dedication meets smart technology. Whether you are an elite athlete striving for the podium or someone taking your first steps towards a healthier lifestyle, Galaxy Watch8 provides actionable insights to help you build healthier habits and reach your goals.