This paper addresses the design considerations and challenges faced in developing a wearable silent speech interface (SSI) based on Permanent Magnetic Articulography (PMA). To improve its usability, a new prototype was developed with the involvement of end users in the design process. Hence, desirable features such as appearance, portability, ease of use and light weight were incorporated into the prototype. The device showed a comparable performance with its predecessor, but has a much improved appearance, portability and hardware in terms of miniaturisation and cost.