 SBD LDM on MotoX - 1st Gen - small |  Taska_003 |  Spike for ikeGPS |  Les Mills Smartbar |
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I have been lucky enough to design award winning and innovative products that have helped many companies grow and succeed internationally. Here are a few examples.
Click the above images for more information.
Sketching and Concept Origination
SBD LDM on MotoX - 1st Gen - smallLaser measurement device on phone |  Design for manufacture concept |  Concept sketchArtex Blade Runner. Styling Concept Work done at Fearsomengine 2005 |
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 Concept bulb |  Male and Female Watch Concepts |  Form study sketchSleep Tracker Concept Sketch Work done at ByMethod, 2008 |
 Concept sketchArchitectural Communications. Cover Panel Removal Concept Work done at ByMethod, 2008 |  IdeationClient: CDHB Work done at 4ormfunction, 2014 |  Form study sketchOmnex Display Mount Elevation Work done at Form3, 2007 |
 Notebook LockTightening Mechanism Concept (allows the lock to work with all brands of notebooks) - Patented Work done at ByMethod, 2008 |  Label Holder - Customisation ConceptFormstudy - sketching in 3 dimensions Work done at Form3, 2007 |  IllustrationNomadic Drums Folding Down Illustration Work done at Massey University 2002 |
Ideation and conceptual development is the short stage of the project where there is infinite possibility. The research and workshops have brought to light opportunities, established problems or unmet needs and the designer can build a set of ideas that will form the basis of the product concepts. At this stage I find working in loose freehand sketch format is the most efficient.
Design Development
 Fisker BatteryFisker Karmer Battery pack design. Work done at Form3 2008. I worked on the mechanical detailing of the battery housings and cooling systems. It was a collaborative process involving several teams working closely together. |  Quick and Dirty Ergonomic StudyIndustrial Remote - Form Sketching in 3D Work done at ByMethod 2008 |  Industrial remote ergonomic study Work done at ByMethod 2008 |
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 Rack mounted equipment - creating a brand identity Work done at Form3 2007 |  Label holder Work done at Form3 2007 |  Vitamode Body Measurement SystemWork done at Boxclever 2004 |
 Vitamode exploded viewWork done at Boxclever 2004 |  Omnex Battery packWork done at Form3 2007 |  Gunlach Trowel - Modular SystemWork done at ByMethod 2008 |
 Notebook LockAuto engage and retract lock. Clutch - unlocked Work done at ByMethod 2008 |  Payment Terminal PrototypeWork done at Boxclever 2004 |
Embodying ideas into refined concepts that can be communicated to the wider team for feedback. Ideas meet mechanical solutions.
Model Making and Prototyping
 Scale foam modelsWork done at Diplomat, 2006 |  Omnex Industrial Controller ModelFor ergonomic evaluation in the field. Work done at Form3, 2007 |  Omnex Industrial Controller ModelErgonomic testing. Work done at Form3, 2007 |
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 Omnex Industrial Controller ModelDisplay mount form study - plasticine Work done at Form3, 2007 |  Hospital Head-panel prototypeWork done at 4ormfunction, 2014 |  Vitamode - cardboard modelWork done at Box Clever, 2004 |
 SleepShifter - form studyWork done at ByMethod, 2008 |  SleepShifter - PrototypeSLA or Stereolithography rapid prototype. This is the go-to mechinical assembly verification prototype process. Work done at ByMethod, 2008 |  Fast Track full scale modelWork done at Form3, 2006 |
 Painted watch modelWork done at ByMethod, 2008 |
Prototyping happens throughout the design process. Some products are more suited to begin design and development with physical models, especially where ergonomic requirements are paramount or the material dictates the design possibilities. In this case I like to sketch in 3D, sometimes with plasticine, sometimes whatever is at hand: paper, wire, duct tape. But as the design firms up, more precise methods and more representative materials are needed. And somethimes it's necessary to create models that are suitable for product photography or design verification testing.
I have experience making all types of prototypes; from foam to five axis machining, from micro electronics to architectural installations.
Design for Manufacture
 Les Mills WeightplatesI designed the weight plates and detailed for production, coming up with new innovative ways to manufacture weights to a higher level of quality than has been ever seen in the exercise industry. |  Stanley Smart Measure ProAs the industrial desinger and design director on this project, I designed and CAD modelled all exterior components and worked closely with the manufacturer through testing to achieve signoff. | Omnex 2nd generation ControllerConcept CAD model |
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 Exploded view - Omnex DisplayI designed and detailed the Display module, providing production file set. This was an IP67 rated product and passed the tests without any need for tuning. Work done at Form3, 2007 | battery packDesign detailing |  Omnex Controller with display |
 Sheet metal designSheet metal enclosure for payment terminal. Designed to visa PED standard with anti-tamper protection. Work done at Box Clever, for Trintec, 2004 |  KSI Tissue Slicer - Assembly DrawingWork done at 4ormfunction 2014 |  Kerr Scientific Tissue SlicerThis was one of a range of accessories developed by myself in a short time to meet a tradeshow dealine. This was designed, machined and assembled within 2 months and the prototype was production quality. Work done at 4ormfunction 2014 |
 BCS BAGgateA range of processes were used to prototype and manufacture the BAGgate. These needed to be lowsetup cost and offer the ability to customise later. So extrusion, fabrication, sheetmetal and PU casting were chosen. Work done at 4ormfunction 2012 |  BCS BAGgate kiosk concept overviewWork done at 4ormfunction 2013 |  BAGgate kiosk prototype - openDesign for maintenance. This kiosk opens with a single key, the front panel drops down giving full access to all hardware. Work done at 4ormfunction 2013 |
 ikeGPS SpikeAssembly process testing testing in the factory. Work done at 4ormfunction 2014 |  Spike Assembly TestingLightpipe and button insertion testing Work done at 4ormfunction 2014 |
My knowledge of production process has formed through working closely with many manufacturers throughout the design and build process. These relationships have given me confidence and competence in many areas of manufacture but I always enjoy learning about and trying new processes or applying a known process to a new material to push manufacturers' capabilities.
CAD Modelling and Rendering
Smartbar RenderingRed Dot and New Zealand Design Awards Supreme Award the Purple Pin. Also Best Effect for return on investment. CAD Rendering Work done at 4ormfunction 2012 |  LMI Stacked Rack RenderingCAD Rendering Designed for cost down and ergonomic improvements. Layout and configuration was designed and engineered by myself from the ground up, working closely with the users. Work done at 4ormfunction 2013 |  BCS BAGgate - Mark 1 RenderCAD Rendering Work done at 4ormfunction 2012 |
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 BCS BAGgate Passenger InterfaceRendering black Melbourne design Work done at 4ormfunction 2013 |  Foot ScienceSurface modelling and reverse engineering Work done at 4ormfunction 2014 |
I have used several CAD packages but Solidworks is my closest ally. I have used Solidworks for over 15 years. I am highly proficient in parametric modelling, surfacing and rendering.