Services we offer

Concept ideation is the earliest phase of product design, in which a broad opportunity becomes a set of possible directions. This is divergent work. We push for range before resolution, generating a high volume of ideas through fast sketching, 3D CAD, and rapid rendering, so concepts can be seen and reacted to almost as quickly as they're conceived. Chase the unexpected directions and find the genuinely innovative idea before the obvious one takes hold.

AI-enabled product design is our use of AI tools inside the design process itself, to explore more directions and visualize them faster than traditional methods allow. We use it to generate, iterate on, and render concepts at a pace that lets us see ideas early and in greater numbers. More iterations in less time means more chances to find the right direction, and tighter feedback loops at the stage when changes are cheapest.

Human factors and usability is the discipline of designing products around the real bodies, abilities, and behaviors of the people who use them, and testing with real people throughout the process. We work with full-scale models in our own shop, through anthropometric analysis, grip and reach studies, and accessibility evaluations, alongside usability sessions, A/B preference testing, and observational studies in real-use environments. Decisions are made based on what people actually do, not on what the team assumes, and catching a problem in a foam model is much cheaper than catching it in a customer's hands.

Model-making and prototyping are the practices of building physical versions of a product at every stage of design to test form, function, and feel before committing to production. We build models in-house, from quick foam studies and 3D-printed concepts to high-fidelity appearance prototypes, using FDM, SLA, and SLS printing, CNC machining, and painted appearance models. A physical model settles debates faster than any slide, and it surfaces the problems that only show up once something becomes real.

Hardware interaction design is the design of how a product feels to operate, the click of a button, the swing of a lid, the way a light tells you what's happening. We design and prototype hardware interaction states, including buttons, switches, lights, dials, and haptic feedback, iterating hands-on until each one feels right. You can't fully judge this on a screen, so we build it, hold it, and tune it until the interaction feels intentional.

Robotics and autonomous system design is the design of machines that move, sense, and act on their own, and do it in a way that people can work alongside comfortably. We design the physical form, human factors, and interaction behavior of robotic and autonomous products. These machines have to perform, and they also have to be legible to the people around them, so we design how a robot signals intent and hands off control alongside the ergonomics, durability, and serviceability that decide whether it holds up in the real world.

Creative engineering is where engineering and manufacturing reality meet design ambition, turning a bold idea into something that can actually be built. We treat it as a creative discipline, not just a technical one, developing detailed 3D CAD surface models, defining component architecture and thermal strategy, and working shoulder-to-shoulder with mechanical and electrical engineering teams through DFM optimization and EVT/DVT review. For teams with a clear vision but no clear build path, we figure out how to make it and where it's worth pushing the boundary of what's possible.

Design refinement is the phase where a chosen direction is sharpened into a fully resolved product, detail by detail. Once a concept is selected, we perfect the form and surfacing, lock the scale and placement of branding elements, and resolve the small decisions that separate a rough idea from a finished product. Renderings and CAD get updated to reflect every change.

Color, materials, and finish design is the work of specifying how a product looks and feels to the touch, documented precisely enough for manufacturing. We explore and specify everything from soft-touch coatings and anodized metals to textured polymers and sustainable bio-materials. Our CMF specs include material callouts, texture references, Pantone and RAL standards, and finish tolerances, so the intent survives the trip to the factory floor. Sustainability factors in here too: we help clients choose recycled and bio-based materials and design for disassembly and recyclability, weaving those decisions in early rather than bolting them on at the end.

Design for manufacturing is the work of turning an approved concept into a production-ready product that's engineered for performance, cost, and scale. Our DFMA work includes part consolidation, wall-thickness analysis, snap-fit and fastener strategy, tolerance stack-up review, and material selection matched to the appropriate process. We also define manufacturing strategy and find cost savings, all while protecting design intent and reliability. We've contributed to more than 700 patents across our portfolio.

Packaging is the first physical touchpoint with your customer. We design from the inside out — structural exploration, unboxing experience mapping, brand integration, graphic design, and materials specification. Our work includes 3D modeling, physical prototyping, dieline development, sustainability analysis, and vendor coordination through production.

Manufacturing partnerships is the work of finding and vetting the right manufacturers and specialty vendors to build a product at the quality, volume, and geography it needs. We help clients identify and evaluate contract manufacturers, OEMs, and specialty vendors, basing recommendations on capability fit, quality track record, volume alignment, and geography. We stay involved through implementation, so design intent carries all the way through DFM, DVT, and PVT.

Throughout my career leading consumer electronics teams, I’ve consistently turned to Whipsaw for design support on complex challenges. They’ve repeatedly delivered innovative, award-winning solutions.

Chris Wheaton

Product Engineering Manager @ Meta

Featured projects

Aescape

Fully-Automated Massage Experience

Tonal

Strength Training System

DG Takano

Melior Water Faucet

“Good design begins with purpose. It feels inevitable, like it always belonged here. It has a sense of clarity in the solution, where every detail contributes to the whole.”

Dan Harden, Principal Designer

Chat about your next product idea

FAQ

What is Industrial Design, and why is it important?

Industrial Design involves creating and developing concepts for physical products that are both functional and visually appealing. It’s essential because it enhances user experience, boosts product appeal, differentiates your brand, and ultimately drives market success. Great industrial design drives user engagement, and in a world where the most successful products cultivate fandom, it’s more important than ever.

How does the Industrial Design process work?

The process typically includes user and competitive research, analysis, and concept exploration. This is achieved through 2D sketching, 3D modeling, physical prototyping, testing, and refining. Collaboration with clients is key at every stage, ensuring the final product aligns with business goals and user needs. Designers also iteratively test products with users to continuously validate their concepts.

How long does an Industrial Design project usually take?

The timeline can vary based on complexity, typically ranging from 2-4 months, though it is not uncommon to have engagements that span a full year or more. Simple products can be completed relatively fast, while more complex projects involving multiple prototypes and rigorous testing may take longer. The integration of design and engineering is complex, time-consuming, and it’s something we are exceptional at doing, whether the engineering is on the client team, a third party, or in-house at the client. Engineering timelines often affect the overall timeline of Industrial Design.

Can you help with prototyping and manufacturing?

Yes. We manage the prototyping process, whether it’s in-house or with a trusted partner. Prototyping can range from simple 3D printed models to semi-functional appearance models. Our Industrial Design team also collaborates closely with manufacturers to ensure design integrity is maintained and your final product meets quality, performance, and user experience standards.

Do you protect the intellectual property of my design?

Absolutely. Your confidentiality and intellectual property rights are prioritized throughout our collaboration. NDAs (non-disclosure agreements) are always signed, and any design created during the project is entirely yours upon completion, with payment in full. We can advise on patent attorneys and often develop significant IP in the course of our engagements.

What industries do you specialize in?

We work across multiple sectors, including consumer electronics, home appliances, health and wellness, robotics, furniture, networking, mobility, industrial, life sciences, surgical, medical devices, and more. Our versatile approach ensures customized, innovative solutions tailored to your specific industry needs, and the depth of our experience ensures that solutions are truly innovative - often inspired by sparks outside our clients’ industries.

How much does an Industrial Design service cost?

Cost depends on project scope, complexity, and timeline. We provide transparent pricing after discussing your project goals and requirements, clearly outlining each phase to ensure clarity, affordability, and value. We understand the capital constraints and fundraising cycles of early-stage startups and the complexity of contracting with enterprises of all sizes. Our clear aim is to partner with our clients to find the right path forward.

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