We offer a different approach to your new product ventures based on collaborative entrepreneurship. You bring the new product idea, we provide the product design, development and manufacturing expertise to collaborate on the next big winner.
Overview: Client desired a better method of teaching students general finances such as account deposit and withdraw. Beginning with a pencil sketch, a novel product was developed that included custom rubber keypad, liquid crystal display, PCB controller, software and enclosure, as well as internal card reader, USB port, AC-DC adapter, rechargeable batteries and serialized magnetic strip cards. Contract manufacturer completed 1,000 assemblies.
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Overview: Startup company raised $2M to develop the world’s most versatile handheld fluoroscopic x-ray device using its proprietary Direct Conversion X-ray (DCX) image intensifier technology initially developed in China. Designed a lightweight, Li-ion battery powered “Imagescope” and mini C-Arm with real-time digital video capture, custom image acquisition software and medical industry leading high resolution capabilities.
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Overview: High precision pan & tilt turret was designed for unmanned ground vehicles (UGV) active in military site surveillance. A complex assembly of custom machined magnesium parts, high torque frameless motors and ultra slim bearings enabled a compact, lightweight and highly responsive sensor platform with its drive control electronics onboard. The universal pan & tilt turret was able to mounted with any sensors.
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Overview: Client desired to upgrade its current patented product with additional features and more appealing overall design. Utilizing a sophisticated plastic molded base with two living hinges and multiple snap fit features, a new product was developed that held both a removable custom golf marker and spare key. Overseas contract manufacturer was sourced for orders in tens of thousands of complete assemblies.
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Overview: Baltimore based startup partnered with an established trucking company to develop its patented emergency truck brake that dramatically reduced stopping distances without jackknifing. Working with the inventor and venture team, the final assembled product design, drawing package and corporate identity package were completed. The video presentation of the emergency truck brake in live road tests gained tremendous interest.
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Overview: Consulting with an established sports equipment company in Baltimore several new men and women plastic lacrosse heads that incorporated innovative patented features were realized. Organic shaped plastic parts that meet specific sport rules, avoid patent infringement, require complex 3-D CAD surface modeling and capable of being injection molded, or even overmolded with softer durometers, present a real design challenge.
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Overview: An inventor wanted a simple solution to the common problem of trying to share an armrest on an airplane flight. The client wanted the product to be easily adjustable for various heights and angles for computer laptop use or reading a book, as well as collapsible for compact storage and transport. A clever design with just a few identical plastic parts met all the functional requirements and reduced the number of production injection mold tools.
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Overview: A startup robotics company in Maryland was awarded a $6M U.S. Army contract to design and develop one of the world’s first unmanned ground vehicle (UGV) testbed capable of being human driven or remotely controlled by spooled fiber optic cable. The six wheel chassis with diesel engine and stealth electric motor included a large pan & tilt sensors turret on a telescoping scissor lift mast and remote operator control unit (OCU).
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Overview: Spin out company from Johns Hopkins University was developing the world’s widest field of view (FOV) and highest resolution HMD based on patented optical technology that incorporated 24 tiled microdisplays. A successful patented design produced a lightweight, fully capable virtual reality HMD with numerous manual optical adjustments that considered intuitive human factors during its normal obstructed view operation.
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Overview: Client wanted to develop a well defined new product line of field hockey sticks based on both previous successful designs and newer ideas to better suit the various types of players. The existing field hockey sticks were all digitally scanned, converted into 3-D CAD files, then manipulated to create the desired combined heel, toe, scoop, head and bow shapes. New streamlined product line included 6 different sticks in 3 brand categories.
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Overview: Often a new product idea begins with a simple 2-D sketch. Typically, however, it is necessary to quickly move toward creating full scale 3-D CAD models to generate color renderings to more realistically convey the general product concept. Upon approval of the product concept, the next step is to more accurately detail design the individual components of the entire assembly. A few example product concepts are depicted here.
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Overview: Startup medical company with the intellectual property rights to the original patented cyclical sequential compression therapy system for proper massage and increased fluid flow circulation. The device included an air pump, programmable six valve manifold, plastic clamshell enclosure, custom large button keypad and dual five hose connectors for attachment to leg and arm bladder sleeves. Many thousands were fabricated and sold.
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Overview: Addressing the Consumer Product Safety Commission (CPSC) report on unsafe bunk beds in the market, a patented bed design was created that incorporated an unique solid interlocking post and rail system. The sequential sized, high gloss, furniture grade PVC pipes permitted compact packaging. Professional photographs were used for marketing materials to entice contract manufacturers and bunk bed distributors.
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Overview: Solving the banking industry problem of expensive armored truck cash deliveries for drive-up ATM kiosks, a patented new system provided a method for bank employees to send cash from the bank branch to a fellow employee inside the secure ATM kiosk. The cable driven, dual bent pipe, track system permitted cash box deliveries via a 16 spring loaded wheeled carriage either through an underground tunnel or overhanging canopy.
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Overview: Small Business Innovation Research (SBIR) Phase II grant for the design and development of a pendant controlled robotic research vehicle for the University of Tennessee to investigate the use of cameras and sensors for improved remote driving. Built on an electric golf cart chassis there were two fully controllable pan & tilt turrets for video/FLIR and dual small cigar stereoscopic cameras, as well as actuated front steering and rear brakes.
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Overview: Consulting with an engineering design firm in Baltimore the concept for a removable, secure money pouch was developed for a large PA bill acceptor manufacturing company. The design challenge was to create a disposable assembly in annual volumes of one million that could accept from 1 to 2,000 individual bills, yet still be manufactured at a very low cost. After prototype verification, an extensive CM search was successfully conducted.
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Overview: An industry leading sports equipment company in Maryland was looking for design assistance on their new lacrosse padding product line. A few different upper and lower arm, elbow, shoulder and upper torso chest protector pads were designed for the male lacrosse players. The project entailed 3-D CAD surface modeling of numerous individual components of the final assembly that were to be molded in high definition plastic foam.
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Overview: Designed and developed an operator control unit (OCU) for remote control of surveillance and reconnaissance robotic vehicles. The custom aluminum case included height adjustable large LCD video screen, a smaller touch screen with gps location map overlays, a joystick controller for the remote vehicle turret sensor platform, and a handlebar controller with manual brake, thumb lever throttle and pushbuttons for driving the robotic vehicle.
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Overview: An individual inventor desired to turn a patented basketball shooting apparatus into a commercially viable sports training product. The final design was one of the most portable and low cost devices on the market capable of returning both made and missed shots, and easily mounted on various basketball backboards in three orientations. The production order for the complete packaged PVC assembly was manufactured overseas.
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Overview: Consulted with a Maryland software and systems engineering company developing a covert internet tracking device for a government agency. The plastic overmolded cradle contained six interconnected components that held a personal digital assistant (PDA) with their custom software, mounted GPS board, RF micro antenna and suction cups for window mounting. The RP polyurethane casting process made numerous assemblies for field use.
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Overview: Consulting with a reputable sports equipment company during its initial entry into a new sports market, a few ice hockey shin guards were created. The injection molded hard plastic components were joined with other sewn soft materials for both knee and shin padding. Unique flexing side panels ensured both comfort and adequate protection. These parts required complex 3-D CAD surface modeling for a proper human factors fit.
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Overview: A Pennsylvania product design firm requested assistance for its Maryland based client company that had licensed proprietary technology capable of quickly detecting hazardous airborne pathogens from MIT Lincoln Laboratory. A new automated tray opener was designed and successfully incorporated into the device assembly for simpler user installation and removal of the critical cartridge with an array of photo reactive assays.
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Overview: Medium sized company developing advanced network systems for military special operations (S.O.) had extensive need for mechanical design assistance in developing numerous versions of custom handheld video, radio and media processor devices. All the battery powered products required watertight compartments for their proprietary electronics, micro military connectors, indicator LEDs, and general outdoor ruggedness.
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Overview: Client desired to develop an umbrella that would be resistant to high winds for beach and general outdoor patio usage. Working with both fiberglass and carbon fiber rods in a custom designed central spinning mechanism with 16 pivoting ball and socket joints, a collapsible 8 fabric blade umbrella was successfully designed and rapid prototyped. The complete assembly drawing package and 3-D CAD files were then prepared for production.
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Overview: The client included an inventive physicist and business development consultants with experience licensing technologies. Two functional prototypes were needed that would more clearly visually demonstrate the basic physics principles behind their envisioned new satellite displacement engine. Live action video demo tests taken on an air table at the UMD’s Physics Lab were used for an important sales presentation at ATK Thiokol.
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Client had the product idea for some sort of remote door lock externally operated by a key fob for additional home security. The final design used a high torque gearmotor to rotate a wedged rubber foot up and down onto the floor. Custom control board, initially external for demo purposes, was powered via batteries or AC-DC wall plug. The plastic clamshell enclosure was easily slide mounted to a bracket on the leading lower door corner.
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Overview: The Air Force was developing a fleet of robotic heavy equipment that would rapidly repair a bomb damaged airport runway. Designed and prototyped an aluminum scissor lift mast with a large U-shaped pan & tilt turret that accurately scanned the ground crater with stereoscopic video cameras and laser scanners for both accurate position and volumetric assessment. Popular Mechanics featured the joint development program.
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Overview: Consulted with an individual inventor who desired to develop a portable umbrella stand that could provide both shade and rain protection during various outdoor activities. The final compact design assembly comprised of two telescoping aluminum poles with simple twist locks, universal umbrella tilting mechanism and three adjustable leg extensions with rubber ends and optional flip out ground stakes for secure mounting on any surface.
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Overview: Today many new products are comprised of plastic components as part of a larger complete assembly. Various types of rapid prototype (RP) services are available to 3-D print or polyurethane cast from soft tooling in order to best determine proper Form , Fit and Function (FFF) prior to investing in the more expensive production injection mold tooling. Examples of individual plastic parts and assemblies fabricated by RP processes are shown here.
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Overview: Virginia based client company serving the needs of various national security agencies was seeking assistance in the design and prototype of a novel enclosure for their proprietary vehicle tracking electronics. The battery powered device was covertly attached to the underside of the vehicle chassis of interest via four high strength rare earth magnets that independently rotate for secure bonding to flat or curved metal surfaces.
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Overview: Company client desired to quickly develop a mobile x-ray cart for its portable x-ray device being presented at an upcoming hand surgeons tradeshow and addition to its existing product line offerings. Capitalizing on previous experience with a medical cart manufacturer, a mobile x-ray cart was completed with four extension arms, micro computer, monitor and rapid prototyped mounts for the flat panel detector and x-ray device.
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Overview: Independent inventor had an existing patented retractable shoulder strap prototype for general laptop computer and sport bags made from sewn fabric, foam and two existing cable boxes that retracted folded narrow webbing. Improving on both functionality and manufacturability, a more compact overmolded plastic enclosure with the essential constant force springs and wider webbing were recommended and rapid prototyped.
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Overview: A patented glove was developed attempting to find the optimal balance between natural touch and hi-tech grip for various sporting activities such as football, golf, tennis, baseball or softball underglove, etc. The product goals were to increase overall handgrip, retain tactile sensitivity, maximize air ventilation, maintain manual dexterity. The glove is made from non-slip polyurethane coated polyester knit fabric that stretches and white leather.
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