Industrial Design + Product Development
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.
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.
Pulse Health had a way to measure key biomarkers non-invasively. They were able to measure this biomarker in exhaled human breath and had a small personal device in their stable but now wanted a clinical version.They came to FUSE for help with this device. FUSE took them all the way through prototyping.
One of our key contributions beyond the industrial design was we created user model scenarios to help the team understand how the device would be used. Once we showed a few of these graphic storyboards the team came alive to determine how best the device would be used.
An orthodontist came to FUSE with an idea that can speed orthodontia. The problem is an orthodondist will generally guess at the size of the band he or she needs to use on a particular tooth. More experienced orthodontists are more likely to get this right but they often get this wrong as well. This takes time and wastes bands or these wrong ones need to be autoclaved. Our client wanted a way to measure teeth that would work for an unlimited number of patients. This Orthodontist’s plan was to sell the eventual product to a large orthodontic supplier like Ormco.
We came up with what we called the BandIt. The Bandit was a simple one handed electromechanical device that used a consumable stainless steel loop that would wrap around the tooth and provide a measurement and recommend a particular size band on its built in LCD display.
This was a proactive project providing a solution to the problem of bike parking since most bike have lost kickstands. The problem is you lean your bike against paint damaging poles and then your bike suffers more than cosmetic damage. We got this into Wired magazine and sold into REI. The rubber manufacturer who was pressing BIKEBARK bought the product a few months after we premiered at Interbike.
Florbot was created as a market development tool for GE Plastics (now Sabic) to stimulate material sales in the floor cleaning appliance market. FUSE principle, Toren Orzeck, then in the GE Plastics Advanced Design and Development Group worked with world renowned robotics scientist Allan Branch of Branch and Associates to develop this prototype. The product leveraged bleeding edge technology at the time and GE’s portfolio of engineering thermoplastics.
To use, the owner would take Florbot out of the box, charge him up and and set him against a wall. Like an old graphics fill program, Florbot would circumscribe the perimeter, then sweep the interior area and go back to its charging station when done.
Design-wise we knew the product would always be visible so the design was a combination or architectural and companion robot, think R2D2. We especially like that the dust bin’s handle doubles as a mouth. Additionally Florbot’s cap was made from translucent amber ULTEM. At the time, GE was pushing the idea that copper traces could be imaged directly onto heat resistant ULTEM so surface mount components could be attached directly.
OTC came to FUSE to essentially repackage a PC into an Automotive diagnotic tool. This main unit has a series of accessories that plug into the unit, testing a variety of automotive engine attributes. One of the major design improvement FUSE made to this category of product was to build in the toughness required into the housing. Typically this was a plastic box with external elastomer boot that was an ugly addition. Instead we built a super robust internal chassis and over molded a shock resistant thermoplastic external armor. In addition, the design featured symmetrical controls suitable for both right and left handed users.
FUSE also did an alternative cosmetic design branded as a MATCO unit.
![Camera: DCS460B Serial #: 4601203A Width: 2036 Height: 3060 Date: 12/13/46 Time: 19:08:56 DCS4XX Image FW Ver: 051998 TIFF Image Look: Product ---------------------- Counter: [81] ISO: 80 Aperture: F8 Shutter: 8 Lens (mm): 35 Exposure: M Program: Po Exp Comp: 0.0 Meter area: Mtrx Flash sync: REAR Drive mode: H Focus mode: M Focus area: Wide Distance: 1.0m](https://fuseid.com/wp-content/uploads/2016/05/Genisys-Portrait-Context-451x600.jpg)
A very clever guy came to FUSE with an idea. A better way to set up a grid of rebar that floats within a slab of concrete. This wasn’t a totally new idea, but Kerry, the guy, had a host of improvements he wanted to add and he had a plan to make these really sell. These concrete chairs turn the painful time eating chore of setting up a grid of rebar into literally a snap. The rebar just pops into place at just the right height.Our job was to make them super strong and super cool. We made them feel like the super utilitarian future by instituting this octogonal theme throughout the structure. The octogonal base not only provided visual branding but also helped with keeping the rebar layouts in the field straight. FUSE designed all 27 variations that accomodate different sized bar and different heights. FUSE also redesigned the BIP logo along the way.
HP came to FUSE to get help creating a control station for their almost battle shipped sized Page Wide Web Press , the T1100S. This super sized printing press uses arrays of HP’s patented Ink Jet technology and applies it to a web (paper substrate) that is up to 110″ wide by literally forever. This sort of printer creates the 4 color images one would see on a corrugated box. The print is laminated to corrugated or other substrates in a finishing operation.
Our job was to come up with a work station that would encompass an array of monitors that not only control the print job but also monitor multiple live views of the print/machine in progress and provide an expert system database if any adjustments or repairs are needed to the printer or the print.
The Pillar design includes a flip down keyboard tray if needed and is modular should an HP customer want more than 3 monitors. Of course, our design would need to compliment the T1100S and be built in materials and processes that reflect the relatively low production quantities.
We were told the operator of this printer would never be sitting so we created a Pillar of adjustable and replaceable touch screens. The Pillar design includes a spacer that can be added or omitted should the operator be short or tall in stature. To house the hardware that runs the control station, we created a cabinet with cleverly disguised filter vents to avoid the accumulation of the paper particles that live in this environment. This project premiered at the DRUPA show in Germany in 2016.
When we built Orp, the super smal really cool bike horn/ bike light, we built it to be Remote Ready. Meaning: make a small wired switch that cold be placed under thumb that could go wherever the rider wanted. This simple product makes the Orp experience that much better as you never need to lift a hand to actuate either of Orp’s horn sounds. The REMORP uses a slick dual action switch. Press lightly on REMORP’s bulbous swelling to fire Orp’s loud sound and then press a little harder to fire Orp’s 96dB loud sound. The other cool thing about the REMORP is it provided an update to the Orp product line that worked for all Orps and Orp owners. It’s super neat and you should go to Orpland.com to get one… now!