Consumer product design + hardware NPD

Mechanical Product Development from Requirements to Production Improvement.

I translate product intent into viable hardware by connecting user experience, mechanisms, structures, electromechanical packaging, manufacturing, cost, service, and validation from the beginning.

Review Case Studies Discuss a Product

Start with what the product must prove—not a menu of disconnected services.

A successful enclosure, mechanism, structure, or supplier package depends on the system around it. I define the work around what the product must prove and which technical commitment comes next.

Common starting points

A promising product opportunity lacks requirements or a credible mechanical architecture.
Industrial-design intent needs to become robust, serviceable, manufacturable hardware.
A prototype works once but is not yet repeatable, testable, supplier-ready, or scalable.
Mechanisms, enclosures, structures, or interfaces need stronger performance, reliability, or cost control.

Development lifecycle

Discover. Define. Architect. Design. Prototype. Validate. Industrialize. Improve.

The sequence scales to product maturity and risk. Every stage produces a decision, a controlled artifact, or evidence the next team can use.

Discover + Define

Use cases, measurable requirements, interfaces, constraints, assumptions, and a risk-led learning plan.

Architect

Alternative system layouts, first-order calculations, trade studies, make/buy choices, and a selected direction.

Design

Parametric CAD, surfaces, mechanisms, structures, packaging, tolerances, materials, assembly, and service definition.

Prototype

Fit, function, durability, or process-focused builds designed around the question that can change the program.

Validate

Acceptance criteria, fixtures, test records, failure review, corrective action, and remaining-risk disposition.

Industrialize

Drawings, CTQs, BOM data, supplier packages, inspection planning, pilot-build support, and change control.

Improve

Field, production, supplier, cost, and service evidence translated into prioritized corrective work.

Integrated capabilities

The disciplines required to make the complete product work.

Capabilities are applied as one connected development system, with the depth matched to the controlling technical and production risks.

Product + system

Requirements, system architecture, electromechanical packaging, ergonomics, human factors, service, cost, and risk-led development planning.

CAD + mechanical design

Parametric part and assembly design, advanced surfacing, mechanisms, enclosures, structures, interfaces, configuration control, and production definition.

Analysis + validation

First-order physics, tolerance analysis, FEA, CFD, thermal and vibration screening, prototype strategy, fixtures, test planning, failure review, and corrective action.

Manufacturing + suppliers

Materials and processes, DFM/DFA, drawings, GD&T, CTQs, BOM data, supplier RFQs, inspection planning, pilot builds, release gates, and production improvement.

Engagement models

The level of ownership the program actually needs.

Complete workstream

Own a bounded mechanical product-development scope from current evidence through an agreed release gate.

Senior team capacity

Join an established team to lead architecture, design, analysis, prototype, supplier, or validation work.

Focused technical decision

Resolve one mechanism, enclosure, tolerance, simulation, failure, DFM, or product-improvement decision.

Independent design review

Challenge assumptions, examine the technical record, identify unresolved risk, and return prioritized corrective actions without taking over the program.

Relevant work

See the stage boundary, ownership, and next gate.

Consumer

Direct conversation

Review the product and the decision blocking progress.

Send a short, non-confidential summary. I will reply directly and identify the most useful next technical conversation.

Discuss a Product