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L-3 ProVision® 2 Personnel Scanner

Designed for L-3 Communications, the ProVision® 2 is a compact, easy-to-deploy personnel scanner delivering the same threat detection capability as its ProVision® ATD predecessor using the same consumer friendly millimeter wave technology.

Golden A' Design Award Winner 2013-14
Good Design Award 2013
Recipient of a $245M TSA contract

Process

With the exception of managing the overhaul of a U.S. warship, this was the most collaborative project on which I've worked. Directed by Joseph Toro, the initial effort involved the entire Industrial Design team developing a range of industrial and mechanical concepts covering the entire range of challenges; from operational configuration to packaging and deployment.

After the initial effort, ID team members effectively switched leads during different phases of development. Thus, while involved to some extent in all design phases, my involvement centered on developing solutions for deploying the unit.
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Lex 700 4-Slot Cradle and Cup Key

Designed for Motorola Solutions, the Lex 700 4-Slot Cradle was designed for both rack mount and desktop deployments.

Process

As this effort was part of a larger accessories development program, I worked in collaboration with several other designers. Although my involvement began early in the program's conceptual phase (which included field research), I left the project and then returned specifically to design and deliver the 4-slot cradle. The Cup Key redesign was a subsequent task.

From my blueline sketches, I initially modeled this design in Alias. After client approval, I then re-modeled the design in Pro/ENGINEER using ISDX surfacing tools. This second 3D CAD effort facilitated a more streamlined, iterative engineering final development process with the overseas vendor.

The Cup Key was modeled solely in Pro/E to ensure a close match with the provided cup design; itself modeled entirely in Pro/E by another industrial design team member.
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ET1 Tablet Scan/MSR Module

Designed for Motorola Solutions, this ET1 Tablet accessory is one of two snap-on scan devices; the other being a scan-only solution.

Process

This design was a collaborative effort between the client's designer, myself and another designer, a co-worker I had been mentoring and who did much of the upfront conceptual work.

This particular design was modeled primarily in Alias with detailing in Pro/ENGINEER. Alias duties were shared between myself and my co-worker, while I provided all Pro/E finishing and detailing, and also contributed some engineering CAD and tooling assistance.

Among the challenges were ensuring that the tablet with the accessory attached satisfied not only stringent drop test requirements but also met strict IP standards. The result is a tightly packed form which meets Motorola's high quality standards while integrating into the design of their newly introduced business class tablet.

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Concierge Control Hub

Designed for Motorola Solutions, the Concierge Control Hub was one of two electronic components designed to integrate into a modular, highly interactive, consumer-facing, touchscreen style kiosk.

Process

The design for this hub, a separate optical scanner and a variety of enclosure components was undertaken after an initial approach was reconsidered. My involvement came during this second effort, at which point a number of decisions had already been made, including the design and layout of the hub's PCB and connectors. Consequently, design options for this particular component were limited.

From some rough preliminary blueline sketches I jumped into Pro/ENGINEER CAD. As changes were subsequently made to some elements of the internal electronic layout, I updated and revised the 3D files as necessary; delivering tooling-ready surfaces, graphics files and a CMF to the vendor.

The above images are KeyShot renders.
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"Smart Object" - Cloud-based, Crowdsourcing Networked Personal Safety Device

This networked personal safety device concept was generated by myself over a four-day period for entry into the July 2004 Popular Science/Core77 "Security" Design Competition.

This early concept combining the "internet of things" with "crowdsourcing" predates both Bruce Sterling's "spime" concept (Aug 2004), and Julian Bleecker's "blogject" (post-spime); both of which are similar.

Additional information about this project, can be found on the Core forum discussion thread at: http://boards.core77.com/viewtopic.php?t=2457

Process

By necessity, the process was very streamlined. I generated some quick sketches, modeled the concept in Pro/ENGINEER and rendered in Maya. The user interface and user experience - derived in part from my military navigation background - received as much, if not more, attention than the creation of the visual assets.
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Black & Decker Lids Off Jar Opener

This highly-successful introductory product for a new kind of appliance was designed to fit within the B&D kitchen product line style, with an emphasis toward clean "Eurostyle" geometry.

Process

I was the sole industrial designer on this project; providing everything from initial concept sketches and foam models cut from Alias 3D files, to tooling-ready Pro/E geometry and mechanism design.

Significant effort was made to accommodate a wide range of users; especially the elderly and physically-challenged. A two-handed grip, a spring-assisted lift, an open-position lock for two-handed jar insertion, a spring-loaded turntable and an intuitively pleasant user experience were all the result of hands-on research coupled with empathy for and understanding of the target market.

Reviews for the product were overwhelmingly positive and sales - approximately one million units in the first 18 months - were well beyond expectations.
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Rubbermaid Shotgun Butterfly Mop

This unique mop designed in-house for Rubbermaid combined shotgun-style actuation with a butterfly-style compression mechanism. During informal comparisons to other units, the ID model for this design (assembled, vacuum-formed polypropylene parts) yielded superior sponge compression with less user effort than competitive products.

Molded-in hooks for loop-style sponge pads not only simplified removal and clean-up, but also reinforced Rubbermaid's sponge replacement business. To lower assembly costs parts were designed with living hinges and molded-in snap fasteners.

Process

After a failed initial development effort led by a more senior designer, I was solely tasked with a complete redesign, and delivered everything from concept sketches to a near "tooling-ready" Pro/E file; including 7-degree shutoff angles and an equation of motion written as a relation within the file to confirm operation and conduct virtual interference checks.
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Black & Decker Typhoon Stand Fan

This introduction of Applica's first B&D-branded fan into the product category is a blend of retro streamline with the corporate in-house style in an effort to communicate the power and efficiency of a newly-engineered fan blade. This solution was intended both to accept a much larger fan blade/housing and to have a cleanly-interchangeable user-interface by designing the control panel for tooling inserts.

Process

I was the only industrial designer assigned to this project, and as such was responsible to the development team for managing the design effort; including delivering concepts, generating Alias 3D geometry for models/renderings, and creating the Pro/E geometry for tooling. Additionally, this effort required extensive liaison with and travel to Asian manufacturing sites.
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Rubbermaid ActionPacker Toolbox Program

Rubbermaid's ActionPacker program consisted of three toolboxes (16", 20" and 24") intended for a global market. This was a major initiative in an effort to help extend the brand overseas.

Initially only a new set of toolbox lids with integrated containers intended to fit existing bases, handles and latches, the program scope increased during development to include new bases, single-piece ergonomic latches and new internal organizing trays.

Process

This was my first project at Rubbermaid and as such my role was primarily that of a junior designer delivering a large number of concept sketches for review. Although I was assigned with another, senior designer, I generated all the concepts and worked with the CAD team to get the concept into Pro/ENGINEER.

The above rendering of one of the toolboxes, the 24", was generated in Alias from the CAD team's tooling file database. The blueline sketches were for the more important 20" toolbox.
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Rubbermaid Tambour RTA Cabinet

Designed in close cooperation with Target during their transition from big box retailer to design-driven shopping destination, this ready-to-assemble cabinet was inspired by Japanese storage products but aimed at the American garage organization market.

Process

As the sole industrial designer assigned to the project, I worked closely with engineers to solve some basic problems. Styling was largely dictated by existing blow-molded RTA cabinets; however, dozens of assembly options were presented for review along with Pro/ENGINEER part files.

The most significant contribution to this product was presenting a dual-material, flexible slat door solution as a means to resolve a conflict between die size limitation and consumer assembly concerns. Unfortunately, the team's engineer and our vendor decided to patent my idea, and I was only unaware of this when the lawyers started asking questions (after which, I presented the original concept sketch).
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Rubbermaid/Richell Unicot Storage Cases

Low-capital investment product design program for entry into an already-crowded Japanese storage products market - conducted in cooperation with Richell.

Process

I was paired with a more senior designer from Richell and sent to Japan to work on-site at the Richell factory. However, on arrival in Tokyo, I had the privilege of meeting buyers for Japan's major hardware chains and gaining first-hand knowledge of their market. Additionally, significant in-home research was conducted while developing the product in Toyama.

While in Japan, we generated a mountain of concept sketches culminating in two designs presented as orthographic drawings and perspective renderings.

With my concept chosen to move forward, upon return to the U.S. I created my first Pro/E model from which SLA's were made and sent back to Richell for approval. At that point, the design left my oversight and some changes were made, but generally the original design remained.
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Ames ReelEasy Hose Reel

This design effort, a collaboration between myself and two co-workers, was Ames' product line initiative to update aesthetics.

Process

My primary contribution was defying guidance by focusing on user experience instead of aesthetics: moving the top-mounted storage tray to the bottom, counter to client and management instruction, thus allowing items to remain stowed while the unit is moved, and allowing a handle to potentially fold down for efficient long-term winter storage.

I was royally chewed out for defying guidance.

However, the concept survived. As initially presented, the tray relocation was shown and I presented the folding handle idea as an option.

The client said little. Left the office. But returned a few months later asking us to continue work on my idea. The final design includes stackability for improved palletization (Ames' idea).

Designed in the mid-90's this product continues to sell long after having set a new industry standard.

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