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In reality, any of the other categories can be considered Product Development: the process of concept through production. I’ve set aside this category to introduce the key development phases and present a few of the medical, safety, entertainment and general products I’ve worked on.
I have experience in each of the following phases:
- Ideation/Concept: Sketching, sculpting and market research
- Digitizing: Reverse engineering or data acquisition to capture existing forms
- Aesthetic Design: digital CAD modeling and traditional methods including sculpting
- Engineering Design: Structural and mechanical design, tooling design and materials selection
- Prototype development: CNC machined, rapid prototyping (SLA & FDM), casting, etc.
- Production: Limited quantity or high-volume with some experience in packaging.
- Testing: Performance evaluation, quality inspection and failure analysis including NDT.
A few of the clients I've worked directly or indirectly for are:
Military/DOD
Laser Eye Protection: Rockwell Scientific
Data acquisition for a study on thin film application for military laser eye protection. Laser scan data was referenced to an anatomical model for exact pupil to lens distance mapping.
A similar method was used to develop a lightweight industrial head mounted display (HMD) for the DOD.
Medical
Digitizing can be used to aid in the design of complex, organic shaped devices or products custom designed to a patient's body.
Some medical products I've worked on include:
- Facial implants (silicone nose and chin implants)
- Orthopedic braces
- Dental tools
Royce medical brace and silicone chin implant.
Furniture
Digital design allows for direct-to-tooling manufacturing and rapid time to market.
Harald Belker Designs, Fiberglass chairs and tables sprayed with soft-touch paints.
Film
Commercial props:
Data acquisition and rapid production of a master pattern for a TV commercial prop. The end product was series of Pontiac Vibe "backpacks."
Motion Picture:
Fantastic Four: Rise of the Silver Surfer
Rapid five month design-build for multiple film vehicles and the Dodge sponsored Fantasticar employing 100% digital (direct-to-tooling) design allowing for peak production efficiency and seamless transfer to visual effects, video games and toys.
