Engineering Products for the Real World

I led the mechanical and structural development of the Snugg Sofa platform, a modular seating system engineered to ship within a single parcel-sized box suitable for standard shipping carriers while maintaining the functionality and comfort expected from the Lovesac modular furniture ecosystem. The architecture separates the customizable arm styles into individual boxes selected by the customer, while the core structural system—including the front beam, back structure, and suspension—ships together in one compact package. I engineered the primary furniture structure and all supporting bracketry, along with a tool less consumer assembly system using custom pins and thumbscrews to enable fast and intuitive setup. The design preserves key platform features such as removable, washable covers and modular configurability, while introducing a pivoting seat suspension mounted on a rear bracket that allows the seat to lift for convenient under-seat storage access. The result is a durable, scalable modular sofa system optimized for both logistics efficiency and user experience.

I led the design and development of the motorized storage product line at SmarterHome, engineering a modular system that enables customers to safely lift and store large items near the ceiling of their garage using Bluetooth-controlled motorized lifters. I managed the full engineering team across both mechanical and electrical disciplines while overseeing product architecture, supplier sourcing, and development through production. As part of this work, I redesigned the core lifter drivetrain by optimizing the gearbox architecture to significantly improve strength, durability, and long-term reliability under high loads.

In addition to the core lifting mechanism, I designed the modular ceiling track system that serves as the structural foundation for the product ecosystem, allowing multiple accessories and lifting modules to mount and reposition easily. The platform was engineered to allow up to four synchronized lifters to link together, enabling customers to raise and store large or heavy equipment such as bikes, storage racks, and outdoor gear. I also designed many of the application-specific sheet metal lifting interfaces used for different items, including bicycle mounts,  5th-wheel trailer hitch storage systems, Jeep top storage systems and more.

 The resulting product ecosystem created a highly adaptable motorized storage platform that combines robust mechanical design, modular mounting architecture, and intuitive wireless control to simplify overhead storage for a wide range of applications.

I also led the development of automated window covering systems at SmarterHome, including both motorized roller shades and blinds designed for simple installation and reliable daily operation. The systems were engineered with integrated rechargeable batteries and solar charging panels, allowing them to operate wirelessly without the need for permanent electrical wiring while maintaining a clean and efficient installation.

I collaborated with Devos Outdoor as a contract design and principal‑level engineer, helping evolve early lighting concepts into a cohesive, production‑ready ecosystem of outdoor products. In that role I owned the full product cycle end‑to‑end—taking rough ideas and requirements, developing them into detailed CAD models, resolving the mechanical and electrical architecture, and working through the many practical decisions required to turn concepts into hardware that performs reliably in the field.

For the core telescoping tripod light, I designed compact, weather‑resistant housings that integrate internal rechargeable battery packs, waterproof USB‑C charging, and angled, downward‑facing LED arrays to create a comfortable “room lighting” effect when the light is raised. Dimming is a fundamental capability in all models, and newer iterations introduce Bluetooth connectivity for app‑based configuration and control. I contributed broadly to defining and refining the feature set—how users manage brightness and runtime, select between different LED panel combinations, and interact with the system in a way that feels natural in real outdoor use.

The platform was intentionally developed as a complete ecosystem rather than a single stand‑alone product. I engineered a snap‑on 360‑degree motion sensor that mounts to the telescoping pole and integrates electrically with the light, with fully adjustable range, sensitivity, and time‑on settings that were later extended to include control through the app. I also designed a modular auxiliary battery pack that attaches quickly to the light, can be used in multiples that connect together to extend runtime as needed, supports solar charging for extended off‑grid operation, and provides power‑out capability for devices such as phones. The external form, mounting interfaces, and connection geometry of the light were carefully considered so that accessories, additional battery packs, mounting hardware, and future attachments could be added without compromising durability, environmental sealing, or ease of use.

Beyond engineering and design, I established a global supply chain capable of producing these products at scale. This included supplier selection and qualification, design for manufacturability, support of prototype and pilot builds, and refinement of production processes until quality and reliability targets were consistently met. Once the designs and supply chain were in place, production could continue with minimal ongoing engineering support.

Across these projects—spanning products from approximately 800‑lumen task lights to 15,000‑lumen high‑output systems—my work demonstrates the ability to take a product from early sketch through detailed CAD, integrate mechanical and electronic design, shape a user‑focused feature set, and put the manufacturing and supplier foundation in place to deliver durable, scalable, market‑ready solutions.