About
Concept to
production
Industrial designer based in Calgary, Alberta. BSc (Hons) Industrial Design, De Montfort University.
- 15+years taking products from concept to production
- 100sclient projects at a design consultancy
- 4areas of work: consultancy, public-art fabrication, film-prop fabrication, in-house loudspeaker design and manufacturing
Research → production
Capabilities
Design
- Research and competitor analysis
- Briefs and specifications
- Sketching and concept generation
- Ergonomics and user interaction
- Photo-real renders
- Presentations to leadership
Engineering
- SolidWorks, surfacing, PDM
- Static FEA, factor of safety
- Drawings: shop, QA, GD&T
- Prototyping: FDM, SLA, SLS
- Acoustic and field testing
- Certification: CSA, IECEE CB
Manufacturing
- Injection moulding, multi-shot
- Sheet metal and welding
- CNC machining, 3 to 5 axis
- Casting and extrusion
- Vac-forming and composites
- Soft goods and finishes
Leadership
- End-to-end project ownership
- Timelines and critical path
- Stakeholder sign-offs
- Vendors in China and locally
- Mentoring and hiring
- 5S and Kaizen improvements
Range Products in this portfolio
- Loudspeakers and rigging
- Transport covers and carts
- Guitar effects and loopers
- Medical devices
- Microphone arrays
- Film props and public art
Tools
- SolidWorks
- KeyShot
- Rhino
- Illustrator
- Photoshop
- PowerMill
- CAMWorks
- Jira
Process
How I work
Written for PK Sound's mechanical team in 2025. Built on the double diamond, human-centred design and the iterative design cycle:
- M1
Research
Learn what exists and why the project matters, so every later decision has evidence behind it.
- Competitor and analogous products: mechanisms, rigging, finishes
- Draft brief and specification
- Cost model, timeline and critical path
- M2
Concept
Prove the idea first, then iterate fast. Three concepts go to review and one direction moves forward.
- Proof of concept: built, tested, documented
- Many quick prototype loops
- CAD with every major part roughed out
- Brief and specification finalised
- M3
Development
The broad strokes are set. Every part is now refined for the process that will make it.
- DFM and DFA review: draft, wall thickness, tolerances
- Final prototype, ready for certification
- Drawings with shop-floor feedback built in
- Tooling started on the critical path
- M4
Finalised
One review with every stakeholder, then a clean handover to production.
- Stakeholder sign-off
- Assembly and user manuals
- Alpha and beta builds, with customer feedback
- Certification approved
PK Sound · 2024 – 2025
Process and leadership
Engineering, the woodshop and manufacturing now work from one source of truth. A thorough SOP sets each team's responsibilities and who signs off each review, so fewer errors reach the shop floor.
Day to day
- Vendors in China and locally, with a written selection policy
- Materials traceability SOP and part labels
- A T-nut legend that fixed frequent assembly errors
- Training and mentoring new staff
Packaging cost reduction · one-day project
In one day I benchmarked competitor and appliance packaging, found where we were overpaying and set the plan with supply chain. The savings came quickly and beat both targets.
- −50%cardboard cost, target
- −25%foam cost, target
- >25%less foam per Ts15
- ~75%less storage space