Inside Samsung’s Computational Design Lab: How AI Is Shaping the Future of Wearables

Creating wearable devices that feel comfortable while delivering accurate performance has always been a challenge. Since every person’s ears and wrists are different, achieving the ideal fit requires more than traditional design methods. To address this, Samsung is turning to computational design — combining AI, advanced computing, and large-scale data analysis to engineer wearables with greater precision.

At the center of this effort is the Samsung Design Innovation Center (SDIC) in San Francisco, where Samsung develops next-generation wearable experiences through its Computational Design Lab.

According to Federico Casalegno, Executive Vice President and Head of SDIC, Samsung’s approach focuses on using technology to create more human-centered products rather than asking users to adapt to devices.

Turning Comfort Into Measurable Data

Unlike conventional testing that relies on smaller user groups and subjective feedback, Samsung’s computational design process transforms comfort and fit into measurable data.

The process combines three core elements — real user data, digital twins, and robotic validation. Samsung captures detailed 3D and 4D scans from a diverse global user base to create digital human models. These models are then analysed through AI-driven simulations and physics-based testing before being validated through robotic testing systems.

This allows Samsung to optimise wearable designs based on objective insights rather than assumptions.

How It Improved the Galaxy Buds Experience

Samsung applied this methodology directly to the development of the Galaxy Buds4 series.

Using hundreds of millions of ear-related data points and running over 10,000 simulations, Samsung refined the earbuds’ structure to improve stability, comfort, and audio performance. Small adjustments to shape and fit resulted in noticeable improvements in long-term wearability.

The same computational design principles are also being applied across Samsung’s broader wearable lineup, including Galaxy Watch and Galaxy Ring devices.

The Next Stage of Wearable Innovation

Samsung sees computational design becoming a core foundation for future product development.

As its internal datasets continue expanding and AI tools become more advanced, Samsung expects simulations to become increasingly accurate, helping unlock entirely new wearable experiences focused on comfort, sensor accuracy, and user interaction.

By combining AI, human-centered design, and advanced testing methods, Samsung aims to make future wearables smarter, more comfortable, and better adapted to the people using them.