Process | Expertise

 

Experience Design | Research

To varying degrees, all product designs are experience designs. Industrial Design as a discipline proposes to understand the experience that exists between people and products and ultimately the experiences that those products enable. It is in this context that designers encode an understanding of that experience in the product design itself making it more attractive, accessible and even more serviceable and environmentally responsible.

Most projects begin with a research and reference phase to understand the context within which the product will function. It is often during this phase when we discover missed opportunities, and are inspired to create more elegant solutions.

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Product Design | Illustration

I don’t illustrate my ideas so I can remember them later… I illustrate them so I can remember them NOW.

Sketch communication is a fundamental skill and a critically important tool for capturing and conveying ideas and solutions. At times, the quality of a sketch can affect the quality of the resulting design solution. Probably one of the more soulful and enjoyable aspects of being a designer is having the opportunity to pull shapes, ideas and experiences from a page of paper.

After design reference and research, this is where much of the work of design begins.

 
 

Prototyping | Testing

Somewhere between conceiving of an idea for a product and cutting steel on an injection molding tool there are important validation steps that must be taken. One such validation step is the design, preparation and construction of physical prototypes.

It just so happens that I was one of the first customers for a 3D printer. While working at Orion Research in 1998, I became the second or third customer for the then-new Z-Corp rapid prototyping machine. This machine built parts by printing a water based binder onto fine cellulose powder and repeating this process until the part (printed one layer at a time) was complete.

Things have come a long way. I now have three Rapid Prototyping systems at home including a Markforged Onyx desktop printer illustrated here. The machine is capable of printing fully functional prototypes for small scale devices and parts within hours. This speeds the validation process, improves the part designs and increases the confidence of the design team when we move toward production and ultimately “cutting steel tools”.

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Plastic Injection Molding

Over my career I’ve overseen the design and production of hundreds of custom plastic injection molded parts. Illustrated here is the housing tool for the Cue table radio. The tool is fitted in a 600 ton hydraulic press. A unique feature of this particular design is a “blossom” style tool where the sides slide and expand the tool in very direction as the tool is opened. This removes the need for exterior draft on the plastic housing giving the product a unique “straight” look.

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Printed Circuit Board Design and Assembly

I’m not a PCBA designer, however, I’ve built small design teams and overseen the development of dozens of designs from system architecture flow charts all the way through parts selection, layout and production with 3rd party manufacturers in Asia and the US. Pictured is an amplifier board for the Cue wireless home entertainment system.

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Compliance and Safety Testing

Compliance is not a black art. It’s a design task like any other. I’ve had the good fortune to ferry several finished products through emissions and immunity testing as well as domestic and European safety testing. With the right development process in place, products can pass through compliance testing on the first shot. (I’ve done that). But it takes discipline and a great design team to adhere to a development process that allows for this kind of predictable success.

 
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Finished Goods Manufacturing and Assembly

For half of my career I designed products that needed to be manufactured in a variety of spaces including medium to high volume CM’s in Asia and in some cases very high tech but small volume facilities here in the US. Over the past 10 years I’ve designed products to be manufactured in my own assembly facility at Cue. The process involves planning, process prototyping and testing, time studies and work environment design. Great products are often the result of great manufacturing processes.

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