Product Design

Overview

I provide innovative product design solutions for the consumer, industrial, medical, scientific, military, and transportation industries. Whether a one-off custom medical device or an electronics enclosure mass-produced in the millions, your project can be seen through any and all stages of design from an initial concept up to manufacturing. I create  designs optimized for function, cost, and aesthetics using a less-is-more philosophy that considers every detail. I am passionate about creating quality, beneficial, and successful products.


CAD

CAD Computer Aided Design Technical Drawing 3D Model

Computer-aided design has revolutionized the way products are designed, with its capabilities increasing each year. I utilize top-of-the-line software and techniques to produce the highest quality results in the most efficient manner, giving my clients the best possible value. I stay up to date with the most effective technologies and techniques to provide highly functional and competitive services.

My primary CAD tool is SolidWorks® Premium 2017, arguably the best and most widely used and recognized CAD package for high-end professional users. I run SolidWorks® on a dedicated, top-of-the-line overclocked and water-cooled BOXX desktop workstation specifically built for this purpose. It is currently the fastest commercially-available computer for SolidWorks® modeling in the world. My experience with SolidWorks® includes four years of formal education and academic use during my mechanical engineering degree studies and full-time professional use since early 2011. I also routinely utilize Adobe® Illustrator®, Autodesk® AutoCAD®, Autodesk® Fusion 360 Ultimate®, Autodesk® Remake®, DS Photoview 360™, and Meshlab™ software. See the Software and Equipment sections near the bottom of the page for more information.

My abilities include, but are not limited to organic shapes, machine parts, complex assemblies, 2D cutting files, files for 3D printing, file conversions, files for manufacturing, 2D to 3D conversion, computer simulations and analysis, parametric modeling, photorealistic rendering, 2D dimensioned drawings, bill of materials, and tolerancing. I am able to import and export essentially any 2D and 3D file type there is. 

Computing
To make the most of top-of-the-line software, you need top-of-the-line hardware. I utilize a performance-optimized, custom-built and designed in USA BOXX APEXX 2 2403 workstation with an overclocked and water-cooled 4.8 GHz Intel® processor, 64 GB RAM, M.2 PCIe SSDs, and professional-level graphics. For multitasking and shared rendering and simulations I also have a Dell Precision workstation with a high-speed CPU, tons of memory, solid state drives, and professional-level graphics.  I have Apple machines to compliment my workstation. To optimize my efficiency I use time-saving and ergonomic peripherals, including 3x 24" Dell UltraSharp displays, a 3Dconnexion 3D controller, a trackball mouse, custom-programmed hotkey input devices, and sit/stand desk.

Software
Today's design software is an order of magnitude more powerful than that used in the not-so-distant past. I utilize top-of-the-line software that I have carefully selected throughout my years of experience, with SolidWorks® being my primary design tool. But using sophisticated software means nothing if you don't know how to harness it's capabilities. This is where I shine. I am intimately familiar with each program I choose to use and have invested the time in properly learning my tools. I have been using SolidWorks® since day one of my engineering education, and have been a full-time professional user of the software for the past six years.

My frequently used design software:

  • Adobe® Creative Cloud® suite, including:

    • Adobe® Acrobat® Pro DC PDF editing software

    • Adobe® Illustrator® CC vector graphics editing software

    • Adobe® Lightroom® CC photo editing software

    • Adobe® Photoshop® CC raster graphics editing software

  • Autodesk® AutoCAD® 3D CAD software

  • Autodesk® Fusion 360® 3D CAD software

  • Autodesk® Remake® 3D scan processing software

  • Cura 3D printing slicer

  • Meshlab™ 3D mesh processing software

  • Microsoft Office (Visio, Excel, Word, PowerPoint, etc.)

  • SolidWorks® Premium 2017 solid-modeling 3D CAD software, including the following add-ins:

    • Autotrace

    • CircuitWorks™

    • eDrawings™

    • FeatureWorks™

    • PhotoView 360™ photorealistic rendering software

    • ScanTo3D™

    • SolidWorks® Composer™

    • SolidWorks® Design Checker

    • SolidWorks® Electrical

    • SolidWorks® Flow Simulation 2017

    • SolidWorks® Inspection

    • SolidWorks® Motion

    • SolidWorks® PCB 2017

    • SolidWorks® Plastics

    • SolidWorks® Routing

    • SolidWorks® Simulation

    • SolidWorks® Task Scheduler

    • SolidWorks® Toolbox

    • SolidWorks® Utilities

    • SolidWorks® Visualize photorealistic rendering suite

    • TolAnalyst™


Design For Manufacturing (DFM)

Molten Metal Casting Pouring Manufacturing Steel Factory

By considering manufacturing throughout the entire design process, I can not only ensure it is possible to produce your product, but that it will be optimized for manufacturing methods that are tailored to your specific needs.

I am an expert at designing for the following manufacturing methods:

 Laser Cutting Sheet Metal Manufacturing Fabricating
CNC Machining Milling Routing 5-axis Aluminum
Sheet_Metal_Bending.jpeg
CNC Machining.jpg
Water Jet Cutting Aluminum Metal CNC Manufacturing
  • Plastic Injection Molding (PIM)

  • Metal Injection Molding (MIM)

  • Machining:

    • CNC Milling

    • CNC Turning - Lathe and Swiss Screw

    • CNC Routing

    • EDM (Electrical Discharge Machining)

  • Etrusion

  • CNC Milling, Routing, and Turning

  • EDM (Electrical Discharge Machining)

  • Laser Cutting and Engraving/Marking

  • Water Jet Cutting

  • Swiss Screw Machining

  • Milling

  • Lathe

  • Metal Spinning

  • 3D Printing/Additive Manufacturing

  • Punching

  • Casting

  • Stamping

  • Bending

  • Screen printing

  • Pad printing

  • Thermoforming and Vacuum Forming

  • Anodizing

  • Chemical Etching

  • Welding

  • Blow Molding

  • Dip Molding

  • Rotational Molding

  • Routing

  • Assembly

  • High-Volume Production

  • Low-Volume Production


Reverse Engineering and Redesigning

 Measuring inspection probe CNC reverse engineering and re-engineering 3D CAD

Through the use of accurate measuring tools, 3D scanning and/or photographs, I can take an existing product and precisely replicate it as a 3D CAD model. Existing designs can be modified to your specifications or can be used as a starting point for a new product. I can tell you how an existing product was manufactured or how it works and provide suggestions on how it can be improved.


3D Scanning, Photogrammetry, and Photography
Professional imaging equipment with a diverse collection of cameras, lenses, lighting solutions, and accessories.

 Mitutoyo Digital Micrometer - part of my collection of precision measuring tools

Precision Measuring
A highly-functional collection of precision measuring instruments including calipers, micrometers, indicators, angle measuring tools, screw pitch gauges, hole depth gauges, feeler gauges, squares, and precision rulers from industry-leading brands like Mitutoyo and Starrett. I have the capability of repeatedly measuring with an accuracy and resolution of 0.00005 inch (0.001 mm).


Computer Simulation and Analysis

Static Force Linear Computer Simulation with SolidWorks Premium

See the stresses, strains, deflections, deformations, motion, interferences, temperature distributions, fluid flows, wind loading, aerodynamics, and failures related to your product before spending a dime to build it. Cost effectively test, iterate, and optimize your design in a short time frame.

I use SolidWorks Simulation Premium to perform:

  • Finite Element Analysis (FEA)

  • Static Force, Thermal, Frequency, Buckling, Drop Test, Fatigue, and Pressure Vessel Simulation

  • Linear, Nonlinear, and Linear Dynamic Analysis

  • Motion Analysis

  • Tolerance Stack-Up Analysis

  • Fluid Flow Simulation

  • Simulations and analysis can be performed on individual components or entire assemblies

  • A blazing-fast overclocked and water-cooled purpose-built 4.8 GHz BOXX workstation and supplementary workstations allow for quick results, high mesh densities, overnight scheduling of consecutive simulations and load-sharing between multiple PCs, so I can provide fast and economical simulation results that don't skimp on accuracy or resolution.


Photorealistic Rendering and Animation

Accurately visualize your product without needing to first have a physical model built. Renderings can be used to aid in the design process, entice investors, and create marketing materials. They often can better showcase your product than professional photographs of the real thing, and can be used on your website or as a catalog image.

Photorealistic renderings can be produce once there is a 3D CAD model of your product. The visual properties (material, surface finish, color, etc.) of the different components of your product are individually fine-tuned. The lighting and environmental settings are carefully selected to show off your product. Renderings can be exported as high-resolution images in any image file-type (JPEG, PNG, BMP, etc.). I have the computer power to produce the most accurate and high-resolution images you will ever need. Batches of multiple renderings can be scheduled to run overnight, allowing for quick turnaround times and cost savings.


Feasibility Consulting

Can your envisioned product be manufactured? Is it's intended functionality even possible? The vast majority of new product ideas are never realized, often after a huge amount of time and money has been expended. I can provide the vital information you need to know before heavily investing in a new idea. I can estimate design costs, prototype costs, and manufacturing costs as well as tell you if your desired product is functionally possible. I can provide solutions you have not considered and help determine the best way to proceed. Identify risks and choose the most promising direction early on. This could easily be your biggest ROI.

Get an opinion from someone who hears thousands of new product ideas every year and has seen what is successful and what flops. In just an hour, I can provide you with initial direction, potentially saving you thousands. I won't hold back ideas. If I see any flaws or major obstacles that will need to be overcome, I will be brutally honest with you.

Send me any relevant info pertaining to your product and we can schedule a time to talk. I will review your idea before our discussion, do any necessary research, look for challenges, and brainstorm ideas. We will then have a meeting where I can try to answer any questions you may have, give my opinion on the idea, suggest manufacturing methods, give cost estimates, etc. Pricing starts at $100 for a one-hour meeting (and prior review of your provided information).


IoT Mechanical Hardware Design

Iot Internet of Things Mechanical Hardware Designer

I can contribute an essential piece of the development of your IoT (Internet of Things) device - the mechanical hardware. This can be as simple as an enclosure for your electronics that is refined for both manufacturing and aesthetics, or involve complex moving mechanisms that form the core functionality of your product. Products can be smart home devices, industrial devices, and any other connected physical product. I have a wealth of experience collaborating with other designers, including electrical engineers, and can work to seamlessly integrate the mechanical and electrical components that form your device, I can also serve as manager of the project, coordinating the various components (electrical hardware, software, UI, UX, packaging, manufacturing, etc.), while also performing my mechanical device duties.