In addition to working with established brands, I have had the privilege of designing for individuals with new product ideas. There is a joy in collaborating with both kinds of clients, but these ones in particular can be very fun - especially when the client is trusting right from the start. With this project, our goal was to develop a body drying solution that was embedded in the wall - something that doesn't exist currently in the market. After starting with a variety of concepts, we were excited about a direction which revealed a slim panel of venting that extended the full length of the body. The form immediately conveys its function and it provides a full body experience. I created a series of mock-ups to test a theory on louvre geometry that could optimize airflow laterally - resulting in a wider exhaust trajectory from the device. Finally, at the last round of design, I provided our client with two aesthetic options - one, minimal, timeless, and pure; the other, inviting, intelligent, and futuristic. Now, I’m sure you can tell which avenue was chosen by the refined engineering model and CMF renderings. This product is about to hit the market next year and is currently going through a short run of 20 units.
This design was for a client who wanted a task lamp that could be positioned directly above a computer monitor to light the keyboard and desk surface without the undesirable glare on the screen. The arms of the lamp can articulate in any direction and fold neatly for a minimal packaging solution with no setup or assembly required.
Featured on Uncrate
Fully funded on Kickstarter
As part of a U.S. Army funded initiative, Tool worked through years of research to develop insights to use for developing a mouthguard for the military. We lab tested dozens of materials, created forming dentitions for testing existing product, orchestrated speech analysis sessions, and even compression molded blank guards to trim and comfort test.
Our final phase of work included a commercialization effort, so we connected with one of the largest manufacturers to build the best solution on the market. While working with Shockdoctor, I worked out a variety of mouthguard concepts designed to improve impact protection, communication, forming and fit. We paired our thinking with the brands industry knowledge and resources to manufacture the guard domestically.
The final design is built with three core materials that each play a part in the functionality. The outer layer protects against impact and raises the jawline to improve breathing, the mid-layer shapes to the teeth and creates the snap-like retention, while the inner gel layer provides the comfort on the gums after forming. The biggest challenge was engineering the lamination geometry so the materials remain bonded before and after the consumer shapes the guard in hot water. We solved this by interlocking the layers in unique ways along the jaw pads and on the side walls.
Work completed in 2018
Available at Shockdoctor online store.
As an outdoor enthusiast myself, working with Jetboil was a dream. I remember picking up the original product in REI when I was just entering the ID world and being so enamored by the design for its utilitarian approach and its clever features. Now, i’ve helped them visualize the next big step for their flagship product! This is the premium cook series - a version of their backpacking stove solution that includes a fuel regulator in order to offer a wide throttle adjustment. This enables the user to control the heat with greater precision and cook more styles of meals on the go. The goal here was to develop a burner system that integrated with the pots in a modular way so that each size cookware could be used on the same compact base unit.
As always, we start with initial concepts then refine to a smaller set of ideas shown here. Then, boiling it all down to a single direction that shows the details necessary to evaluate the design before moving into formal engineering - which was being executed in-house. The nesting of system components as well as the pot interface was the main focus. It was a sort of complex puzzle as the stove needed to fold and collapse in order to fit within the pot when the product is not in use. It was a huge challenge, but the team over at Jetboil was really excited with my “bloom” concept after the second round of design. It neatly nested under the standard fuel canister geometry and maximized the already limited space available. The burner pot supports reduce the chance for mis-use by the curved shape of the unfolded arms - a small design constraint I had that I think is super nuanced but quite brilliant. It minimizes the instances where people would try to use the stove in a dangerous way.
One bonus feature that I developed was the handle mechanism - a unique solution that allows the user to choose from 3 positions - storing, cooking, and eating. A simple rotation of the anchor allows you to flip the handle around and lock into any usage angle. A simple cast part and a spring steel release enables this function and offers an interaction that no other brand has thought up! Pretty cool.
Eagerly awaiting the release of this product.
Work completed in June of 2022
Playing lacrosse growing up was a blast. It was a dynamic and innovative sport and I loved the gear that came with the competition, especially the helmets. Cascade was always the brand of choice due to the sleek design and edgy, aggressive style. Never did I expect to be doing the design work on what possibly could be the next big development in their product!
We were tasked with thinking though mechanisms that would allow the face mask to flip up when resting from play and flip down when toughing a good tackle or stick check. The solution had to be robust and resistant to inadvertent release yet, easy to activate with a glove on. As usual, starting with a mild to wild approach - I created a set of concepts that explored a variety of solutions. The styling of the helmet itself was not the focus, however, the lines and parts needed to look great in both open and closed states, so that required some thinking beyond the latch components.
Work completed in Spring 2023.
Currently still in development at Cascade.
While working with the DOD and Shockdoctor, I created a series of concepts to tell the story of the collaboration between the Army and the premium mouthguard company. Ranging from standard bister-pack style directions to more unique stand-out ideas like the MRE bag. Each camp is paired with a case and showcased in an end-cap display and graphics that weave in the background behind the product.
Work Completed in 2020
Being a MTB rider myself, this design and production effort was a treat. Taking an idea originally drafted by a design student at WIT in Boston, TOOL leveraged several design phases to explore various fastening methods and style attributes. Our client’s goal was to create a unique knee pad that opened in the back so the rider could easier dress the protection without needing to slide on up the leg or take a shoe off. He did in fact have a rough proof of concept when we engaged and it used the magnetic fidlock buckles - however, he was open to exploring other style of buckles or fastening. Inside the sleeve is a proprietary layering of impact protection and antimicrobial cushion padding. I was involved in every phase of design and engineering to help bring this product to life. I collected brand and market research, created a variety of first level concepts, rendered the final design in photoshop, built the final tech pack and 3D model for the pad inserts as well as all the sample evaluation and updates.
Project Completed in 2020
Having the opportunity to work on the next generation Guardian cap was quite rewarding knowing it could be a huge step in player safety across all levels of football - one of the most popular sports in the country. Guardian Sports already possessed a monumental piece of equipment that was tested and proven to mitigate impact forces and dampen loud sounds that result from the clashing of helmet plastics that damage players eardrums. The goal of the new design was to enhance the aesthetics without altering the functional benefits of the garment. Ultimately, that meant using the same materials and padding structure and rethinking the style and shape of the flat pattern and compression molded areas. Still, no simple task when you're working to cover a spherical surface. There was also a focus to enhance the fit and retention of the cap to the helmet - another challenge since there are a variety of helmets to which it needed to attach to.
My team created a variety of concepts before selecting a design to move forward as the evolutionary approach. We explored a wide range of construction methods in addition to the current layup. I was directing the effort and the interface with the client and once a direction was agreed upon, I created the final tech pack artwork and worked with engineering to ensure the geometry aligned with the design vision.
Guardian caps are already making their way onto the field during primetime matchups so keep your eyes peeled for this new product making headlines.
Designed in 2023
Set to release in 2025
Glasful creates a milky cup of vapor to enjoy with friends. A glass to be exact. The contents so dense it behaves as a liquid. Utilizing a gravity system to push water into the glass then back out creates a vacuum to draw smoke from the bowl into the glass. The mechanism was originally conceived by our mad science teach client (literally) but aesthetically upgraded into this sleek machined aluminum design. After two rounds of concept sketching, I derived a way to adjust the stand for various style glasses and control the flow of water manually. Several functional prototypes were then built for the client to show to investors.
Nemo is an outdoor gear company located in Dover, NH that offers premium camping and backpacking solutions. They got their start in the industry as the first company to design an inflatable tent. Since then, they have been building out their product lines and expanding their production capabilities. Tool partnered up with Nemo to design and engineer a set of tent hardware that could reduce their sourcing limitations and cost structures. Believe it or not, most tent brands utilize rigging hardware that has already been developed by alternate vendors. So, cost of goods are somewhat driven by these components. Nemo wished to invest in their own custom hardware - thus teaming up with TOOL (me) to spin up some really unique solutions.
There are various hardware elements to this tent that required our attention - the “foot” having the most connection points and therefore being the most challenging component of the bunch. I arrived at a clever design that could be stamped out of metal and insert molded to create all 5 connection points. This piece was located at the base of the tent at all corners, so it needed to be robust and durable. The rain fly (water-proof cover; second image; orange fabric) connection is a simple 90 degree key turn lock which makes it super easy to take on and off depending on the weather.
The second most important hardware element is the pole hub. This piece needed to be lightweight, strong, and minimalistic. In addition, it had to be elegant since it was at the center of the tent and at eye level. With that in mind, I developed an ornate cast metal part through a series of design iterations and FDA analysis with a branded plastic cap that neatly conceals the inner shock cord tie offs.
I am still amazed at how complex all these little parts are and how much function is packed into them per volume of material. This was my first collaboration with the Nemo squad and not the last. Can’t wait to share some cool new gear that we are currently working on.
Work completed 2021/2022
Product released 2023
Neurosensing is cutting edge technology breaking news headlines right next to the revolution of AI. It allows researchers to tap into the brain and use it as an interface. Really mind-controlling stuff.
Working with leaders in tech, even if they are in their infancy, is exciting but also challenging. The client needed a design and visual assets in very short order. So, I lead the effort through 3 phases of design and built this final model to help them meet their goal. With this project we were tasked with creating an adaptive sensing headset that could pair with the newest Varjo VR goggle. In addition to 8 sensors embedded in the rear, the mask supports an array of facial sensors that needed to fit to any size individual. We leveraged a system that adapted to all heads using internal cable tensioning. This solution could tighten the sides and top straps in unison and relocate all the sensors with one easy turn of a dial. Pretty easy huh. Now, all you have to do is shell out 25k to get your very own.
Work completed for TOOL in 2021
CES Innovation Award Winner in 2023
A clever group of young entrepreneurs trained at MIT developed a therapeutic system for middle age women dealing with hot flashes. The solution is a thermal cycling unit connected to a cooling pad that recycles water to keep the user comfortable during the night. TOOL was tasked with designing and engineering the complex base unit that had to house a water reservoir, and a thermoelectric cooler, a heat sync, a pcb, and a fan of course. For ID, this involved creating an elegant form factor that fit in with modern decor. The device exterior required venting, a hose interface, a few buttons, and a fill port.
The design started with a few configurations of the internal components. Those configs drove the form proportions. Some decisions were made at this stage based on the location the device would be living in - under the bed or on a bedside table. The Amira team thought it would be more desirable to position the base unit under the table or bed to keep the surfaces free for the wrist band which was being developed at another firm. Still an interesting decision to split up the design between two firms, but invited a unique challenge to coordinate and match the design language.
The buttons are cleverly positioned along the top edge of the device so that it can be pushed under the bed or table but still remain accessible. The water reservoir cap is easy to open by the push of a button in the center. It flips up with a spring and seals back up just as easy.
Designed in 2022
Project currently in manufacturing.
Gillette was a great account for TOOL while I was just hitting the ground running at the firm. This women’s gel dispensing razor was one of the first projects I was put on. The Gillette team had already been testing a preliminary solution with focus groups as we began to help with the new ID. This was a long project. We went through dozens of iterations. The stand-up element, im proud to say was my idea. The concept sketch shown here was the first time that part of the design was introduced. We were moving several “camps” of thinking along while another team at Braun in Germany was doing the same. It was quite exciting to have parallel efforts happening by the prestigious Braun team. None-the-less, the final product was mostly by our hand with some compliments from their work.
Work completed in 2018
Product launched in 2021
I worked intimately with the product team over at Fox Racing to develop new innovations in Moto boots. Close attention was put on the comfort and protection of the ankle while maintaining the freedom of movement to shift gears on a bike. Our working relationship with Fox was fluid and dynamic which allowed us to get out in the field to test prototypes and observe and interview pro riders. My concept art and boot mock-ups lead to advancements in key areas of the boot. I also created the artwork and synthesized months of R&D efforts for a final presentation to the CEO.
In addition, TOOL was tasked with developing storyboards to propose new innovations and propel discussions and company wide. I lead the group in a comprehensive research effort to identify key areas of opportunity for the company, then created illustrations to present at the annual innovation summit in L.A. at FOX headquarters. The boards helped guide a two day event and served as a visualization of potential R&D roadmaps for the upcoming years.
Collaborating with operators throughout the design phases was one of my favorite parts of this project. Being able to gain valuable insight into their procedures and necessities was hugely helpful when working to develop this piece of equipment.
This device enables operators to mount their radio(s) on their back while still being able to switch channels and control the volume. Freeing up space on the front of their tactical vest allows them to move easier and mount more important gear or more ammunition. One of the most interesting interactions that needed to be considered was the use of the dials. Operators need to be able to use the device in the dark or without looking so the two dials needed to be differentiated from each other and have a tactile feel when moving through channels. In addition, the dial needed a hard stop at channel 1 so they could count from that index and know exactly what number channel they were selecting.
My first effort was to create a set of concepts so that our client could include them in their SBIR submission. With those assets (round one concepts shown here) they were able to secure funding and hire us for the rest of the development.
After the initial design effort (round 2 concepts shown here), the client decided to pivot in regards to the mounting location on the vest and thus the configuration of the components - rotary encoders, PCB for buttons, etc. I then utilized the first 2 phases of engineering to rethink the design based on their new direction. My model was used to develop the first prototype they they showed at Shot Show in Las Vegas.
Design Completed in 2021
Currently in production.
These concepts were part of an accelerated effort to produce a variety of forms for a new product Ninja was engineering. Much of my experience with the brand has been very exciting sprints where we quickly move to what we called “cowboy CAD” - models that are quickly built, sometimes in rough feature trees, but create compelling surface models for iterative rendering. This is just a small selection of the work that lead to their product launch.
Rocketbook brought TOOL on board to help conceptualize a premium version of their reusable notebooks. When I became involved in the project, I proposed the idea to laminate a hard cover similar to that of a tablet case. After I prototyped a sample and added some polished space-like magnetic binding rings, everyone got very excited with the direction which in turn strengthened the client relationship. This also catapulted us into a retainer agreement with them to do the full development of the product.
I leveraged 3D printing to rapid prototype iterations of the magnetic spine and worked through how it was assembled to the polyurethane cover, deciding where to embed the magnets and refined the hooks that secure the metal binding rings of the page packs.
The new premium protective cover introduces a new rigid surface for writing and a modular magnetic spine which accepts a variety of interchangeable page pack styles. It can flip around and fold flat for use on your lap or in the air - just as the original units did (but better of course). The elevated space-like aesthetic matches the companies brand story and builds upon the success of the core reusable system. My design has been received very well by the dedicated Rocketbook community as well as new customers and has over 200 reviews and a 4+ star rating.
Work completed in 2019.
Available at getrocketbook.com
I have been fortunate to work on a variety of kayak designs in the past but this fishing style boat was a favorite of mine. Moving through ideas quickly with a feature rich product such as this was a challenge, but also a great experience. Not dwelling on every detail on the concept sketch helped my work evolve and my line-work style continue to develop. Usually our projects with Dick’s Sporting Goods are fast sprints and we don’t fully see what happens to the ideas we deliver. In this case, we moved through several rounds of work and later found the team at Field and Stream modeled up something quite reminiscent of my designs.
Work for DICK’s Sporting Goods in 2019
Sharplite is a modern multi-tool for outdoor enthusiasts that run a tight pack. The 3.4 inch blade tucks neatly into a diamond pattern handle and between the two batteries that power the lights at the front of the knife. The lanyard hole is specifically designed to keep the blade stowed while not in use and keep the hand from slipping when cutting. Choose an aluminum or a co-molded plastic body in an array of colors.
Personal Model and Render Completed in 2015
This was a fun little project for the guys who started Rocketbook. They had this idea to use a coil spring to pop out a grip for your phone. It was novel but had its flaws. At TOOL, I suggested we modify the spring geometry to a quad-helix design. This would give it more rigidity and robustness. I spun up a quick model and 3d printed it to prove the concept out. Soon after, we were pursuing that direction and refining the idea further with a TPR coating. It sounds like a simple development process but crafting the grip out of metal and determining the magnetic strength to hold it down when not in use but still allow it to be popped up was a challenge. The fabrication of the unique spring design was likely the biggest hurtle.
I also was asked to help with the branding and logo. A few contractors were tasked with this but my proposed design stood out and thus was chosen. The "T" resembles the side profile of the product with a plate on top and spring geometry below.
It remains one of the thinnest phone grips on the market.
Design completed in 2018.
Available to Purchase HERE
After a successful design effort with the newest Rocketbook Orbit, we dove into another project - the Rocketboard! It was larger, but seemingly simpler. The goal was to quickly mount the board but then be able to reorient it for various note taking efforts. The marker tray was at the center (not literally) of the design focus. It cradled the board and obviously the markers. The board also needed to be attached at the top. An adhesive magnetic tack was the best solution here. The Pocketbook team approached us with a rough prototype that we use to understand the overall interaction and setup - with the goal to improve upon the concept.
It was a quick project compared to our other collaboration with this client but fun none-the-less. I did most of the work with some sketch support from an intern at the time.
I think this project was tabled after discovering the COGS could not allow for enough margin on the product - despite our best efforts.
Expression through music plays a large role in personal development. Outlets such as writing and sketching can be visually catalogued in a sketchbook or journal, however, with a musical instrument, an archive is more difficult to organize. Perch allows its user to record in either audio or video and archive jam sessions right onto your smart phone or computer. Perch will do exactly as its named and stand for nothing but your creativity, transforming your guitar into a musical sketchbook. Now catching all your pure original moments has never been easier.
Personal Project Completed in 2016
It’s been a pleasure collaborating on various projects with Nemo. Their team is sharp and calculated which drives great product development and quality in their business. I can’t say much about this project yet. More of a placeholder, but expect some really cool innovation to come from this space soon.
I had the opportunity at tool., inc. to mentor a talented student on his senior project as part of a collaboration effort with the Marblehead High School. Cole was tasked with designing, modeling, and prototyping a solution to problem in an area of interest to him. It was an great experience to coach him through a portion of our process and teach him some foundational skills. This project helped him understand how a product idea can be brought to life with iterative thinking and CAD modeling. Due to the COVID-19 pandemic, the majority of the project had to be coordinated virtually; nonetheless, Cole excelled at collaborating with us through Slack channels and Zoom meetings and was able to generate some exceptional work. I enjoyed helping him model, render, and print his design.
Cole came up with the idea of developing a trekking stick handle that could be universally installed on any wooden hiking stick. I helped him explore various solutions for attaching the handle before arriving at a unique double collet system that tightens around the stick while allowing for variability in diameters. Its a simple thread to tighten user experience. We added a wrist strap and a built-in compass for navigation on the trail. He was stoked to see the idea come to life and this effort built up his excitement for pursuing design and engineering as a career. Congrats Cole!
Mentoring Project completed in 2020
I use the FormLabs Form 2 SLA 3D printer quite often. Once the parts are finished printing they need to be cured using ultraviolet light. This process fully solidifies the prints so they aren’t sticky from the resin. I built an enclosure for our design studio, tool. Inc. with only a few parts ordered online and laser cut birch plywood. Have a look!
Heres what you’ll need to make your own:
1. 1/2” birch ply
UV Filtering Acrylic sheet and LED lamp
- (1) 12″ x 24″ fluorescent orange UV resistant acrylic sheet ($14.75 per sheet)
- (3) 110v 20w 395-405nm UV LED lights ($42.99 per light)
- Mortise-Mount Hinge with Nonstandard Hole Pattern Non-removable Pin, Square, Zinc-Plated Steel, 1″ x 1/2″ Door Leaf
- 2 Magnets for the door (2 steel screws with spacers do the trick on the panel side)
- 7 Nylon Unthreaded spacers – 1/2in OD 3/8 length
- 1 1/4 inch Steel flathead wood screws
Finally some sweet flat pattern design files that I’ll flow your way just shoot me an email.
This 20 oz water bottle keeps it simple with a single wall triton build to maximize capacity and a rugged tpr base plate to shield it from drops. Its drinking spout flips out with a push of a finger loop and automatically closes when you start carry it. Its form is not only unique but functional in its ergonomics. The triangular form is easy to hold and even keeps your water from rolling away from you if it finds itself on its side. Get your own online. Currently in production.
Work Completed in 2015
Living with diabetes requires being on top of your glucose levels. Current systems for testing blood are overcomplicated, cumbersome, and often call for multiple devices for this one task. With Scout, you can pop in a single cartridge with both needles and test strips in the morning and be prepared all day. No more separate devices. Scout's interface is meant to be simple and efficient with a single readout for your blood sugar number and eight dots that correspond to the number of needles left in your clip. Everything you need in your pocket. Scout's sleek design keeps you cool and collected in a public setting.
School Project completed in 2012
Squeezasnak is a handy little to-go container for moms and youngsters looking to take a healthy snack in the car, at school, at the park, practically anywhere. Forget all those disposable puree packets and whip up your own delicious mix for your kids and keep your waste footprint to a minimum. The body is made from food safe reusable silicone so snacking can be squeezable and fun.
Available online at CoolGear.com
Work Completed in 2014
Stroke is one of the leading causes of long-term disability and the number of cases within the US has reached almost 800k in a given year. Following a stroke, victims often manage chronic limb impairments which can limit their quality of life and sense of independence.
This device enables users who are struggling with hand impairments to perform basic daily tasks such as pouring a beverage into a glass, opening a bottle, or putting on clothing. It is worn on the arm that has lost either full or partial dexterity over the hand. The innovative electromechanical technology allows control over the prosthesis using wrist actions performed on the same hand or buttons activated by the opposite hand. The gripper can be calibrated to various compression settings or switched between modes via the wrist plate. Two balanced batteries along with sensors, actuators, soft plastics and large buttons make it lightweight, comfortable and easy to use. The approachable design looks and feels like a wearable consumer device, attempting to break the mold of conventional medical prosthetics.
I provided Boston Incubation Center with a number of concepts and a surface model to fully visualize the refined design direction. The model was handed off to engineering to which a prototype was created to test and assist in commercialization efforts. Learn more about the SBIR Program.
Work Completed in 2017
Up-cycling artifact. Iron wheel barrel wheel for a modern sheik apartment.
Collaboration with Carson Artz
Drift wood not only looks stunning but it has a sort of wisdom to it. The journey through the ocean has given the wood a quality that only time and distress can elicit. Who knows how long it has been surfing the waves or where it has come from or who it had belonged to. When you find a piece like this, you don't have much choice but to give it a new purpose and the recognition it deserves.
