Selected Work

Products that made it to production.

Each program below is documented the way we run it — challenge, approach, design, engineering, manufacturing, outcome.

Health & Wellness

Wearable Health Monitor

Concept to CE-marked production hardware in eleven months.

Challenge: A clinical team had a validated sensing algorithm and no path to a wearable product that patients would actually keep on.
Approach: We ran a four-week discovery to fix the use case, wear time target, and unit economics before drawing anything.
Design: Industrial design centered on a single-material enclosure and a strap system that survives daily wear.
Engineering: Mechanical, electronics, and firmware developed in parallel with weekly integration builds.
Manufacturing: Two-cavity tooling with a domestic supplier, plus a validated QC plan for the first 10k units.

11 months concept → production

38% BOM reduction

10,000 unit first run

Hardware & IoT

A minimal sensor platform designed to disappear into the room.

Challenge: The client's v1 was accurate but ugly, expensive, and impossible to install without a manual.
Approach: Teardown, cost model, and a rebuild plan that protected the sensing stack and replaced everything else.
Design: One-piece housing, magnetic mount, zero visible fasteners, single status indicator.
Engineering: Board respin for lower power draw and an onboarding flow that pairs in under thirty seconds.
Manufacturing: Sourced a new contract manufacturer and moved to a single-tool assembly.

2.1x battery life

44% lower unit cost

Sub-30s install

Robotics

Fifty part iterations in six weeks to lock a mechanism.

Challenge: A robotics startup needed a drive mechanism proven before a Series A hardware demo.
Approach: A prototype cadence with build, test, and teardown every 48 hours.
Design: Design language kept deliberately raw — every part optimized for test, not for show.
Engineering: Load testing and tolerance stacking documented against each iteration.
Manufacturing: Transitioned the winning geometry into machined parts with a production-ready drawing set.

50 iterations / 6 weeks

Mechanism locked pre-raise

Full drawing package

Consumer Products

Moved a stalled overseas tooling program back on schedule.

Challenge: An inherited tool package was producing parts out of spec with a supplier that had stopped responding.
Approach: Full DFM audit, defect mapping, and a supplier transfer plan executed in nine weeks.
Design: Geometry revised to remove sink and warp without changing the exterior surface.
Engineering: Tolerance analysis and a revised gating strategy validated on short-shot samples.
Manufacturing: Tool transferred, re-cut, and requalified with a documented inspection standard.

9-week recovery

Scrap rate 12% → 1.4%

On-time launch