Industrial Design – FUSE Industrial Design

MARWALL POD

VACUUM PACKED.

A couple of entrepreneurs came to FUSE with a big idea: they wanted to reduce all the CO2 and waste created by single use disposable containers. They wanted to replace all these earth killing, land-filling, leaky containers with a collapsible silicone container that diners could bring with them. This sounded good, but these containers exist. The pandemic certainly didn’t help either.

We thought, “This isn’t good. We can’t take their money to make another plastic container….”. We brainstormed. We drew concepts. Like we always do, we explored. We also knew the pervasiveness/success of all the insulated water bottles. Could we bring this insulated utility to food?

We hated all the fussy bento box-like little containers. Who eats like that? People are eating bowls of low glycemic index carbs and proteins. Or, imagine if you’re a frutarian, wouldn’t cold watermelon be good at noon? Yes it would. Do you really want to risk that thirst quenching red goodness to the office fridge? No you do not. You know your so called trusted office mates are food thieves! Maybe it’s a sign of security that they know you well enough to eat off your containers. Beyond food security, we also imagined other uses (e.g. a nice product to take on day hikes, a way to carry temperature sensitive medicines, etc).

We did some concepts and shared them with our world saving duo. The team liked it. Now we had to find a way to make this product something other than cylinder shaped. I’d get into the details, but you’ll notice almost all twin-walled, vacuum sealed stainless steel containers are cylindrical. There are lots of You Tube videos on how these are made, but our soon to be Marwall Pod would require a new path towards commercialization. This was a problem.

We scoured the world and located a company that believed in our team’s vision and they found a way. Armed with this confidence and this new factory partner, we forged ahead. FUSE did multiple thermal studies and realized we needed a twin walled lid to achieve the insulative properties we wanted. We added utensils (keen observers will recognize this as giving a nod to ancient Inuit tools) and stored them on the inside of the twin walled lid. We sealed the pod and the twin walled lid with a silicone gasket. Sliding latches with rotatable carabiner-able loops lock the lid to the base.

We imagine the metal part can last a lifetime or more (barring a fall off a cliff), but the plastics (don’t worry — they’re BPA-free Tritan) while tough, may succumb over time. All these parts are replaceable, so your pod will last a lifetime (if not cut short by a climbing accident and we know you’ll only be thinking about your Marwall Pod in that event…). We are so confident this is a lifetime-plus product, inside the metal container there’s an area to engrave to whom you want to bequeath your Marwall to.

NED (NOT BREAD)

EDIBLE PACKAGING

A few summers ago we were on a camping trip with another couple and one of the partners had a gluten allergy. We had stopped at drive-thru for a quick refuel on the way back. The gluten free friend (GFF) had ordered a vegan burger with a lettuce wrap to avoid the bun. What a mess! There were condiments all over her hands and subsequently, my car! Not only is the gluten a problem, it’s also the high carbs of that bun. A typical burger bun is some 40 grams of high glycemic index refined white flour. There had to be a better way.

When we got back to or studio, I grabbed ( hang on, not physically) a colleague and we brainstormed. I always loved the genius of the edible ice cream cone, especially the one inaccurately named the “cake” cone. I did a little research and these wonders of industrialization, a literal injection molding of water and flour are only 6 grams of carbs and that’s with rice flour. And, it gets better…, if you use almond flour, you can bring the carb count down to zero! Not to mention how brilliant the whole family of edible packages are! Taco shells! Sushi! And then.. wholly cow , and start digging in more, and did you know the average common restaurant – remember those , burrito flour tortilla can be 80 grams of carbs!!!

The big idea was to make a small edible piece of luggage, kidding, not luggage but a bread or tortilla replacement that could be gluten free if needed and lower carb. This is good for celiacs, diabetics and everyone that wants to lower their ingestion of high glycemic index carbohydrates. By the way, the term “Keto” was Google searched for more than Subaru in the Pacific NW.

In terms of design, this concept allows almost infinite shape, color, texture and flavor. This concept can replace anything where bread is simply a carrier. Think pizza, tacos, burritos, all the bread shapes, even low carb snacks like crackers can be NED. Best of all if you were brought up by TV like some of us were, then you’ll love the brand-ability of this concept. See the images above.

Knowing there’s a fair amount of tooling (though relatively inexpensive per mold) to make these things, we approached the Joy Cone company with NED. They are biggest ice cream cone maker in the U.S. with plants in Pennsylvania and Arizona. Joy makes special branded cones for some of their largest customers.

I don’t want to say we’re brilliant, but I think given the hand friendliness, this qualifies as thumbelievable!

Ok, shutting up now – have a look!

ANAND SPORT POD

Serial entrepreneur and avid competitive tennis player, Dr. Rahul Anand (he’s an anesthesiologist), was annoyed when he saw college and pro tennis players throwing sweat laden towels on the court after wiping off. Initially, he had hoped this was just a rare occasion, but it continued to happen. Dr. Anand even contacted the players and/or their management teams to make them aware of the hygiene problem this towel discarding was causing. Still, no change. Exasperated, Dr. Anand decided to take this problem on. This is where FUSE comes in.

Armed with the problem Dr. Anand was trying to fix, FUSE got to work. FUSE retraced the research, and for sure, this problem is a new animal. Not that it’s rare, just that its not been recognized. Lots of products start this way, we as humans adapt to situations. Look at what TESLA is trying to do with the removal of stalks.

After numerous concepts and a couple of full scale prototypes. A tight production budget started to provide clarity. Our team and Dr. Anand settled on the Rocket concept. Initially the Rocket was a single part roto-molded creature. It would hold towels, warm-up clothing, balls, hydration and personal items (phones, keys , wallets, etc.).

While initially designed for tennis, our team imagines the pod being valuable in multiple venues. The Sport Pod is at home pool side, beach side, in the gym and in the world of hospitality. With available accessory trays, the Anand Sport Pod is the perfect guest at your next barbecue.

In order to ship around the country, the world, and not ship air (or cost more than the product), we worked with the molder to make the the legs snap on. It fits into a FEDEX and UPS friendly box and sets up in minutes with no tools.

ARIEL CHAIR

When they go low, we go high.

The Ariel chair is an update to the Crane chair. This new version adds a visually thicker mold-able cellular structure that conforms to the users’ body.

The Ariel Chair features that same elastomer powered lift mechanism that allows users to set up standing desks and sit only when needed. Users can sit and lean against the Ariel with its easily locked casters. Ariel’s more minimal i-Back encourages active postures.

Complex only 3D printable structures are super intriguing, but really hard to make. At the moment, 3D printing while compellin,g is unbelievably slow compared to modern injection molding. This design creates a thermally neutral cellular surface that is cleanable and most importantly, mold-able.

Sciatic Stretcher

Athletic Trainer Taylor Peasha and professional Deep Sea Diver Steven Macdonald came to FUSE for help designing a super versatile training aid. Combined with some simple exercises and stretches, the medium density elastomeric ball provides just the right amount of point load to massage knotted muscles and compressed nerves.

On the engineering front, the big innovation is we use a single injection molded part that is simply flipped over to hold the strap securely. This part features a snap finger that locks to itself.

OTTOLOCK PRO MOUNT

The OTTOLOCK has been a break away success for OTTO, but the company was looking for a more stable mount for their coiled genius. OTTO came to FUSE with a physical model that was pretty close and FUSE worked with OTTO to refine their idea and prototype the refined design.

FUSE refined and simplified the design to separate the mounting to the bike function and the securing of the lock to the mount function.

ABOM HEET GOGGLE

The ABOM Heet is the newest snow sports goggle from ABOM Labs. The Heet is incorporates the latest fog eviscerating technology from ABOM. A built in moisture sensor auto magically eliminates the fog creating condensate from inside the goggle. The Heet is sleeker and offers a better fit for both men and women. The tighter chassis also fits most snowmobiling helmets so those riders can enjoy a clear, fog free ride as well.

SofStick

After a friend’s kid got hurt while playing with a stick, we had an idea. Why not make a safe stick? All kids love sticks, right?! SofStick is that safe stick. Made from elastomeric bead foam (think that molded packing foam that protects your new iMac), Sofstick provides all the fun of a real stick without the stabbing risk. Also, SofSticks float so can easily be a replacement for a foam pool noodle and be an all season toy. We designed a 46″long sword size SofStick and a thicker SofLog version.

ABOM POWER PACK

ABOM wanted to extend run time for their unfoggable goggles for the endurance athlete and those that engage in expedition activities. This meant designing an external power pack with a larger lithium ion battery.

We made the design fit the body with a gentle curve like a nice flask. We were sensitive to the potential for disconnection and keeping the pack weatherproof should the skier/snowboarder/snowshoer/ explorer take a spill. Beyond the industrial design, FUSE added convenient, logical features like a flashlight and additional USB port for charging a cell phone or other accessories.

MO’GRO’ FITNESS MOWER

FUSE had done alot ot work with FISKARS’ Gerber knife and tool division and then Gerber’s president became the head of FISKARS US operation where they did all the School, Office, Craft (SOC) and Garden products under the FISKARS brand. We were tasked with designing a few SOC products but we had this notion that FISKARS garden division needed to do a Mower. Not just any Mower but a fitness Mower. We’ve all have had experience with these crappy steel mowers that seem to be rusted after only one season and thought: what if we could marry the technology of thermoplastic composites to the simple reel mower. Sort of a TREK OCLV of mowers. FUSE Designer Ahren Laurinate had a good idea of making the mower self-fertilize the lawn by grinding and spreading compost while mowing. This would make the lawn grow faster and thus, you’d need to mow more – perfect for a Fitness Mower. Tory restyled this concept and Lori Katz did the Alias model. What’s shown here is what was presented. FISKARS liked but was afraid of the cost.