Barfoot design

Project M85 is a prototype motorcycle that bridges the gap between motocross and downhill mountain bikes. Utilizing a Kawasaki KX85 motor, high-end mountain bike suspension components, and a bespoke frame, the M85 tips the scales at 135lbs ready to ride. 

Designed from concept to fully functional prototype, the M85 has been featured in multiple motorcycle publications.

The Magpul Ronin is a prototype motorcycle born from Buell's 1125r. Incorporating a linkage front fork with revised steering geometry, front mounted radiator, and ram-air induction, the Ronin weighed 50lbs less and performs better than the donor 1125. The frame, swingarm, brakes, wheels, and motor were the only remaining stock components after the redesign was complete. The Ronin has since been redesigned into a limited production run of 47 motorcycles.

Redesign of Buell's 1125CR. While the Buell 1125CR is a well engineered bike with exciting performance, the aesthetics left a lot to be desired. I wanted to explore another aesthetic option for this platform. Rendered in Photoshop.

Exploring the power of new Ai tools. processing simplified concept sketches and old photoshop renderings through Ai Software to take them to the next level. Incredible times we are living in.

What would a street legal M85 look like? Posed with that question we developed a rendering of the new model and a business plan proposal of what it might take to get it to production.

Protective UHMW-PE Chain Guide for enduro motorcycles. Design incorporates integrated swingarm tab protection. Easy install without removing the wheel or breaking the chain.

Assisted in the design of various aspects of the Lift5 E-Surf Foil.

Design efforts included carbon mast, motor cooling system integration, and quick connect wing mechanism.

Assisted in the development of the next generation of hand controllers for Lift Electric Surf Foils. Was responsible for mechanical design from start to finish. Product requirements included IP68 waterproof ratings and flotation in case unit was dropped out on the water. Design focused on ergonomics, trigger feel, ease of charging, and UI. The controller was designed to be easily assembled and disassembled while retaining waterproof ratings. This sped up development as you could test and retest units, and facilitates warranty customer support after production.

Carbon XC Hardtail Redesign- Responsible for the entire project from concepting, to CAD development of all sizes, to release for production. Designed in OnShape using configured geometry sketches to drive model sizes from XS to XL.

Wanting to get familiar with the new available Ai tools, I generated bicycle concept renderings from rough initial sketches and photoshop “smashups”

Drove the ID direction for a new Enduro EMTB with a 6-bar rear suspension linkage. Responsible for the design and release of all CAD models of the rear triangle and suspension rocker. Involved heavily in the development of the front triangle, motor integration, and development of all plastic components.

Roofnest Condor 2 rooftop tent redesign. Helped develop new shell designs that could be shared across all future products. Focused on shape for increased strength, aerodynamics, integrated structure for mounting internal accessories and external racks.

Roofnest Sparrow 2 rooftop tent redesign. Helped develop new shell designs that could be shared across all future products. Focused on shape for increased strength, aerodynamics, integrated structure for mounting internal accessories and external racks.

Roofnest Sparrow EYE 2 rooftop tent redesign. Helped develop new shell designs that could be shared across all future products. Focused on shape for increased strength, aerodynamics, integrated structure for mounting internal accessories and external racks.

With the advent of 5G mobile networks, cloud gaming is transforming into an experience that will one day rival gaming consoles. Users can now play top level AAA games on their mobile devices from services like Xbox’s Cloud Gaming. What was once swiping a phone screen to play CandyCrush is now playing Call of Duty on your phone with an Xbox controller. Otterbox saw this new emerging space as an opportunity to develop new mobile accessories for a specific user. Through extensive user research, concept testing and product development we create a portfolio of 5 new products, consisting of:

-Xbox Controller Shell

-Gaming Clip

-Hotswap Controller Batteries

-Travel Carrying Case

-Gaming Privacy Glass for Phones

-Heat Management Phone Case

The portfolio of products was well received as

Winner of Rolling Stone’s “Best of CES 2021” award the Otterbox Mobile Gaming Clip allows users to play streaming mobile games on their mobile device with a fully functioned Xbox controller. One handed rapid adjustment allows user to position the phone at a wide range of angles for optimal viewing and weight balance. Clamp has 3 grip arms to help clear buttons on a wide range phones. Grip arms fold flat for compact storage. Clamp utilizes a constant force spring, instead of traditional coil springs, to grip with the same amount of tension regardless of device size. Clamp is removable to play in table top mode. Innovative adjustment mechanism allows fitment for both Xbox One and Xbox Series X/S Controllers.

Xbox hotswap battery allows users to never be tethered to their console again. Through user research we found that a controller dying mid game is one of the biggest pain-points gamers face. They asked for a hotswap solution to allow them to swap a dead battery on the fly and not lose controller connection while doing so. This is the first gaming power product to allow users to swap power seamlessly. Incorporating a high power capacitor to keep the controller connected was key. The packaging constraints were immense, but we were able to pull it off, give gamers a completely new experience, and solve one of their biggest pain points.

The Otterbox Mobile Gaming Clip for MagSafe allows users to play streaming mobile games on their mobile device with a fully functioned Xbox controller. MagSafe module allows iPhones equipped with MagSafe to magnetically attach and secure to the clip. Magsafe Module rotates 360 with detents every 90 degrees orienting the lower MagSafe magnet for different use cases. One handed rapid adjustment of the stabilizing arm allows user to position the phone at a wide range of angles for optimal viewing and weight balance. Phone holder is removable to play in table top mode. Innovative adjustment mechanism allows fitment for both Xbox One and Xbox Series X/S Controllers.

Grocery delivery and pick up has changed the game. Grocers are looking for ways to keep and deliver their fresh products without the need for new refrigerated infrastructure, refrigerated trucks, or requiring customers to be home at the time of delivery. Working with grocers to understand their requirements and needs we developed a line of lightweight rugged coolers and configurable ice packs to help them provide their customers with a better experience. Imagine having your groceries delivered on your front porch without having to be there to receive it, and knowing the products will stay in a safe temperature range until you unpack it. This product is designed to provide that experience.

Insulated, reusable EPP box for 12+ hours of thermal performance

Straight-sided design has the largest internal volume and the width accommodates 2 gallons of milk side by side.

Extremely flexible coolant system accommodates a variety of pack-outs (8 vertical slots and ability to lay 2 ice packs on the bottom)

32°F/0°C and 5°F/-15°C ice pack options, plus dry ice compatible

Thermal divider increases thermal performance and allows for two temperature zones in one tote

Fits gallon jugs of milk and chilled juice standing upright

Securely stacks with common ambient totes, allowing for efficient staging of orders for customer pickup

Fits in most picking carts

Lightweight, durable design

Machine washable for easy cleaning and sanitizing

Wineries are unable to ship wine in cold and hot months as the temperature damages the wine. Setting out with the goal to keep wine within a safe temperature range in a reusable package that was sturdy enough for ground shipping, we created Liviri Vino. These high performance coolers use vacuum insulated panels to offer incredible thermal performance and reduce bulk. Custom ice packs are designed to keep the wine in temperature for up to 5 days, even in the hottest summer months. Two designs ship either 4 or 6 bottles. Customers remove the wine and a carry tote, then apply the included return shipping label to send it back to the winery. This reusable shipping cooler won the 2020 Excellence in Reusable Packaging Award.

Wineries are unable to ship wine in cold and hot months as the temperature damages the wine. Setting out with the goal to keep wine within a safe temperature range in a reusable package that was sturdy enough for ground shipping, we created Liviri Vino. These high performance coolers use vacuum insulated panels to offer incredible thermal performance and reduce bulk. Custom ice packs are designed to keep the wine in temperature for up to 5 days, even in the hottest summer months. Two designs ship either 4 or 6 bottles. Customers remove the wine and a carry tote, then apply the included return shipping label to send it back to the winery. This reusable shipping cooler won the 2020 Excellence in Reusable Packaging Award.

Nominated for the 2024 CES Innovation award, the Otterbox Hardline Series was designed for hazardous working conditions, including Oil and Gas and other potentially explosive environments. Built to withstand steep drops, engineered to protect against flammable gases and vapors, combustible dust and ignitable fibers, The Hardline Series is the world's first UL Certified iPad Charging system for use in hazardous work environments. The rugged case incorporates a Qi charging coil and mates with a wireless charging stand for spark free connectivity and charging. Integrated tether locations allow for a variety of of strap solutions, whether handheld or over the shoulder security. Touch screen compatible work gloves round out the package to give the user full control and protection while operating on-site.

Travel battery pack that doubles as a Qi charging stand overnight. USBC power in, USBC and USBA power out allows the user to charge the power pack plus up to 3 other devices (ex. 2 phones and a watch) overnight.

Otterbox exclusive Ipad cases designed specifically for Apple retail stores.

Perforated leather phone case inspired by perforated bespoke bicycle seats

TPU phone case design inspired by architectural sculpture paneling

Lifeproof Fre redesign to make it thinner, more comfortable, and more refined, while retaining its IP67 waterproof rating and drop protection

Wallet phone case for LIFEPROOF. The wallet flap is on the back of the device to not obstruct the screen. Has a magnetic closure, has 3 slots for cards and cash. Flap holds phone at angle for video viewing

Redesign of Otterbox Defender

TPU mobile cases for popular Apple, Samsung, and Google devices. The design focused on correct fit, button feel, and tactile grip, while material selection ensured that the case did not stick in your pockets, swell over time, and provided a quality feel in the hand. These cases strive to be the best single material cases available, at an honest price point, all while being designed and manufactured in the USA.

Multiple cases in the product line have received Editors Choice awards.

All cases are designed from hand sketches to production ready models in Solidworks.

Overmolded mobile cases for popular Apple and Samsung devices. The design focused on correct fit, button feel, and tactile grip, while dual materials ensures excellent drop protection and provides a quality feel in the hand. These cases strive to be the best overmolded cases available, at an honest price point, all while being designed and manufactured in the USA.

Multiple cases in the product line have received Editors Choice awards.

All cases are designed from hand sketches to production ready models in Solidworks.

Sunglass concept modeled in Solidworks

Adjustable shotgun stock for the Remington 870. Provides replaceable cheek risers for iron sights or an elevated optic and swapable buttpad spacers for an adjustable length of pull. It is an adjustable ergonomic package rarely seen in shotgun products.

Performed DFM of all components and managed product through production.

MIM (metal injection molded) rifle sights utilizing unique detent mechanisms to reduce part count, assembly time, and overall cost.

Designed from concept sketch, through multiple rounds of prototypes, to production ready solid models. 

Winner of the American Rifleman Accessory of the Year Award 2017 the Magpul X-22 Backpacker stock provides a complete solution for Ruger 10-22 Takedown rifles. The barrel portion of the stock disassembles and stows into the rear portion creating a compact package that can be packed easily. The stock incorporates two storage areas, a waterproof compartment in the grip, and a large compartment under the cheek riser.

Designed from concept sketch, through multiple rounds of prototypes, to production ready solid models. 

The PRS Gen 3 is a precision buttstock for AR patterned rifles. It features an adjustable cheek riser, overall length, and buttpad for personalized fitment.  

Designed from concept sketch, through multiple rounds of prototypes, to production ready solid models. 

Awarded "Accessory Of The Year" by American Rifleman Magazine 2016 the Hunter X-22 is an adjustable hunting stock for the Ruger 10-22. The platform provides replaceable cheek risers for iron sights or an elevated optic and swapable buttpad spacers for an adjustable length of pull allows fitment for adults as well as youth. Multiple sling mounting options provide easy handling while in the field. Patented barrel tray allows fitment for multiple diameters of barrels without and extra parts or hardware.

Designed from concept sketch, through multiple rounds of prototypes, to production ready solid models. 

Fixed Carbine Stock for AR patterned rifles, with multiple sling mounting locations, provides a simple, strong stock at an OEM price point. 

Designed from concept sketch, through multiple rounds of prototypes, to production ready solid models. 

Angled forward grip provides a more ergonomic wrist angle for a shooters forward hand. Grip ribs combined with a rear palm support, and front finger stop, provide excellent control of the weapon. 

Designed from concept sketch, through multiple rounds of quick ergonomic prototypes, to production ready solid models. 

Zhukov hand guard for AK-47 rifles. Provides a much larger area for hand placement than traditional AK-47 rifles. Multiple accessory mounting locations to adapt to the users needs. Hidden extruded aluminum heat shield acts as the main structural component of the hand guard and provides superior heat protection when compared to other market offerings. 

Designed from concept sketch, through multiple rounds of prototypes, to production ready solid models. 

Vertical forward grip utilizing a coarse custom texture provides a traditional "broomstick" grip for tactical rifles

Designed from concept sketch, through multiple rounds of prototypes, to production ready solid models. 

Magpul was approached by Remington Arms to create a stock for their new .22 caliber rifle. This rifle was to be a competitor to the iconic Ruger 10/22. The goal was to create a single part low cost stock from glass filled, foamed, polypropylene, while providing simple features and a modern aesthetic. We succeeded . The final part was streamlined, cost efficient and, through clever molded features, included sling and accessory mounts at no additional cost.

Injection molded grips for the Colt 1911 pistol utilizing a custom heavy texture and dished thumb relief for easy access to magazine release.

Designed from concept sketch, through multiple rounds of prototypes, to production ready solid models. 

Polymer handguard mount for Surefire Scout flashlights

The Brown Tree Snake is an invasive species on the Island of Guam. They were unknowingly transported by WWII ships from various South Pacific Islands and landed in Guam. The current population is believed to be approximately 2 million. In Guam they have no natural predators, and have decimated the native bird population. Climbing powerlines they are responsible for electrical blackouts every year. The U.S. Government is focused on eliminating this issue before it spreads to other islands through additional air or sea transport. A 2010 study conducted by the National Wildlife Research Center found brown tree snakes would cause between $593 million and $2.14 billion in economic damage each year if they became established in Hawaii like they are on Guam. Working with the U.S. National Wildlife Research Center, Applied Design, was contracted to concept, prototype a bait delivery system to help with the eradication of the snake population. It was found that Acetaminophen is fatal to the snakes and provides very little impact to the ecosystem. The design brief was to come up with a reliable method of deploying Acetaminophen laced mice into the jungle canopy, utilizing materials that would degrade quickly in the heat and humidity of the climate.

The Shuttle Jogging Stroller was a project I worked on back in 2008. When my skills were still very fresh….before Keyshot or AI existed. The stroller was unique in that it had damped rear wheel steering that could lock and unlock from a handlebar actuated lever; similar to a MTB remote lockout. I wanted to bring this concept back to life and experiment with the new AI tools available to reimagine what the Shuttle could be today.

Concept sketches and Solidworks manifold design for an industrial vacuum.

The Cartable is a compact cart that folds flat for easy transport, hauls your gear from the parking lot to your favorite spot, and then converts into a table.  

Design and prototype focused on overall concept viability, mechanical order of operations, and user experience. 

FUNergy Energy Education Playground teaches kids about renewable energy during play

Wall mounted diaper dispenser for home nurseries. Holds range of diaper sizes and a package of wetwipes. Slot allows user to see need for refills and cover hinges for easy reload. Sticker kits allow user to customize to match the decor.

For an airbrush class, I wanted to paint a fun graphic on a BMX helmet. This was the result.

Solar powered iPod shuffle speaker system with available decals for personalization.