Senior/Lead Industrial Designer

Translated complex user and manufacturing requirements into production-ready industrial spectroscopy sensing devices and systems. Delivered solutions under customer NDAs that generated approximately $16M in annual revenue.

Led a strategic Spirit Sampler redesign that removed $1,800 in unit cost, improved repeatability, enhanced aesthetics and packaging, and reduced assembly time by three hours per unit. Developed an automated pump-system concept that reduced validation time from six hours to 10 minutes, refreshed internal software applications in Figma and XD, improved a Raman spectroscopy module, and resolved critical Class VI medical-probe field failures while meeting ISO 13485, cleanroom, sealing, QA, and manufacturability requirements.

Designed and fabricated ophthalmic inserts and accessories for commercial AR and VR headsets using SolidWorks, rapid prototyping, hand sketching, CAM, and injection molding. Delivered client-approved solutions meeting aesthetic, functional, and cost requirements under nondisclosure agreements.

Created proprietary manufacturing methods for fitting prescription inserts into fully tooled customer devices. Redesigned commercial lens-edging equipment for military field deployment, supporting a $10M U.S. Navy contract, and developed packaging, labeling, and accessories for worldwide shipment. Recommended new prototyping equipment and factory-layout changes that improved throughput and quality enough to consolidate production shifts.

Architected the structural, styling, CFM, and ergonomic redesign of the PS 2000D blood pressure kiosk. Reduced BOM by 27%, component costs by 62%, and assembly time by 72%.

Directed pilot builds and pre-commercial launch activities, aligning regulatory, production, marketing, sales, and service teams to meet market timelines and ISO 13485/TUV requirements. Qualified suppliers and manufacturing processes across PCBA, cables, pressure forming, aluminum casting, machining, and sheet metal; also improved serviceability, manufacturability, packaging, floor layouts, and assembly fixtures.

Conceived and developed four generations of battery cells, stacks, modules, and site-installation systems. Eliminated approximately $1,200 per stack and $600 per module through strategic product design, contributing to $196M in venture investment and multiple U.S. patents.

Completed a $5M DOE grant two years ahead of schedule by designing and building a 1000V grid-tied system. Supported a new factory buildout, specified equipment and processes, and improved product designs for manufacturing constraints, efficiency, shipping, pilot builds, and product launches.

Conceptualized and developed the Beltone Marq/dot by ReSound hearing aid and accessories, a 2008 Red Dot award winner. The product achieved strong fit rates and represented approximately 36% of company sales for three years, with an estimated $500M+ in revenue.

Developed a virtual-fit-study process using 3D scan libraries to improve fit rates for new concepts. Collaborated with European and Asian suppliers and international teams to improve quality, lead time, cost, reliability, manufacturing efficiency, and usability across product lines.

Built high-fidelity form studies, appearance models, and functional prototypes for clients including Nike, LeapFrog, Kodak, Xerox, World Kitchen, Fisher-Price, Corning, Vuzix, and Black & Decker.

Generated product-concept variations through close collaboration with design, sales, and engineering teams. Supported visualization, prototype fabrication, and early-stage product-development activities.

Optimized printed circuit board assembly across product lines using automated optical inspection, 3D X-ray inspection, surface-mount placement equipment, and statistical process control. Trained repair and rework operators and advised teams on design for manufacturability.

Streamlined four PCB products onto one production line through carrier fixtures and re-panelization, reducing annual material costs by $750K. Improved test yields by 30% through redesigned SMT reflow-oven profiles and solder-paste screens, while supporting PCB supplier selection and review.

Provided primary surface-mount production-line support for GenRad production for Ford Motor Corporation and Matrox video-card production. Also provided secondary support for Lucent, Symbol, and Compaq manufacturing programs.

Performed DFM on new and existing customer products and completed Six Sigma Black Belt training. Developed a paste-in-hole reflow process that improved Matrox production efficiency by 48%.

Thesis: Form and Visual Cues - A Workshop for Graduate Design Students, focused on cognitive psychology, form exploration, and intuitive UI/UX ease of use.

Completed summer master's-level studies in 3D form.