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DESIGN

I've held a variety of team and project leadership roles, bringing practical experience that includes 10 years of hardware product development and 15 years of digital media product development, and a strong sense of aesthetics underlying everything I do.

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Below are some examples of my recent efforts, from industrial design to software UI design.

CASE STUDY

1

XR Visor Industrial Design
2015 - 2022
​Project Overview

  • As mentioned in the Engineering section, this​​ Mixed Reality headset is the flagship product of my first startup, FYR Inc. I originally conceived of this device and its operating principles during my time with the Skunk Works® at Lockheed Martin as a means to provide fast, retinal quality MR to pilots of high-performance aircraft, improving situational awareness by spanning their entire field of view while minimizing eye strain and fatigue.

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  • In cooperation with Lockheed Martin following years of internal R&D, we launched FYR in 2019 to commercialize the technology — a rare emergence of Skunk Works® innovation into the public sector.

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  • I wore many hats on this project, beginning with the very first conceptual proof of concept sketches in 2015. Throughout the project I handled all industrial design​​​, optomechanical design, electromechanical design, mechanical assembly, prototyping, and manufacturing. Below is more information on my industrial design work​.

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​Project Vision & Design Objectives

  • Design a slim, lightweight headset approximating the form factor of wrap-around sunglasses

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  • Extend the virtual imagery across peripheral vision, spanning as much of the visual field as possible

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  • Ensure the design adheres to all electrical, optical, and mechanical requirements

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  • Visor unit must be removeable from Frame for mounting with other headgear (helmets, face masks, etc.)

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  • Continue and elevate the FYR brand through consistent styling, colors, materials, and finishes

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Anthropometrics & Ergonomics

  • For reconfiguration with other mounting platforms, I designed the Visor unit as a self-contained device with a common magnetic pogo-pin connection port

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  • The Visor can be securely fastened to the frame with a quick release mechanism, allowing for convenient dismounting and remounting to other headgear such as flight helmets​

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  • Full-field wrap-around vision is accomplished through tiling 88 individual Facets (44 for each left and right Eyepiece)

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  • The edges of the Visor are tapered to reduce the overall thickness and weight

 

  • A central cavity for primary driving electronics and additional sensors lies above the nose, between the Eyepieces

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  • The Frame for common use is tethered to a hip-mounted External Power & Computing Unit (EPCU) to help free the head from additional battery and processing weight

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  • An outward-facing multicolor LED array provides activity and status feedback 

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  • The device is automatically activated by inward-facing proximity sensors when worn

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Industrial Design

Selected product shots and design details

(rendered using Arnold in Maya)

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CASE STUDY

2

XR Loupes Industrial Design
2022 - 2024
​Project Overview

  • As mentioned in the Engineering section, this light field passthrough​​ Mixed Reality headset is the main product of my most recent startup, FYR Medical. The device connects to surgical navigation platforms to provide spine surgeons with a virtual view into the patient's anatomy even before an incision is made.

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​My Role & Responsibilities

  • All mechanical and industrial design

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  • Coordinating with surgeon advisors to capture and represent the voice of the customer, ensuring the design adequately meets all user needs for ergonomics, handling, storage, and performance​​​

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​Project Vision & Design Objectives

  • Design a slim, lightweight headset approximating the form factor of surgical loupes 

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  • Account for the wide range of human adult head / face shapes and interpupillary distances

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  • Ensure the design adheres to all electrical, optical, and mechanical requirements

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  • Headset must be collapsible to fit inside a small case, comparable to conventional surgical loupes

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  • Continue and elevate the FYR brand through consistent styling, colors, materials, and finishes

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TopView_Raytraced.png
Eyepiece.png
Anthropometrics & Ergonomics

  • To maximize adaptability in terms of form and fit, I divided the headset assembly into modular components that can be swapped for different configurations

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  • Each left and right Eyepiece is a standalone unit that can connect to a Bridge​

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  • There are five different Bridge widths accounting for different IPDs

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  • Every Bridge is angled such that left and right optical axes converge at a common 0.5 m working distance (can be further customized per user if necessary)

 

  • Each Bridge can be connected to a Frame which is worn by the user

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  • There are two different Frame sizes to fit both large and small head circumference (can be further customized per user if necessary)

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  • Both Frames have flexible Arms that can be flexed outward without damage

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  • The Arms have slots for two optional head straps to keep the headset securely in place and provide some additional weight relief for long duration surgical cases

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  • The Arms can be folded inward to collapse the Frame, similar to typical glasses

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Industrial Design

Selected product shots and design details

(rendered using Cycles in Rhinoceros)

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CASE STUDY

3

XR Loupes Software UI Design
2024 - 2025
​Project Overview

  • To operate the XR Loupes headset (above), the surgeon relies on a scrub tech to control all operating parameters during pre-op and intra-op phases in the OR. This includes setting or changing everything from the view magnification to the rendering style of the CT or MRI volume. 

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​My Role & Responsibilities

  • Defining the overall UX reference software functionality and vision

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  • Designing the GUI for​ all components, controls, and modules of the host software app​​

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  • Directing and managing a team of developers (both internal staff and external contractors) to implement the fully functional prototype software, written primarily in C++ / OpenGL

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​Project Vision & Design Objectives

  • Design the GUI for a reference software app that controls the XR Loupes headset and interfaces with the host navigation platform

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Design Requirements

  • The app interface should fit on a standard 1920 x 1080 HD monitor, providing intuitive controls for all view settings, user preferences, and operating task functions

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  • Create a surgeon login and profile settings page to store user-specific configuration details and preferences

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  • Display the real-time view of what the surgeon sees in each Eyepiece, as well as the views from both tracking cameras

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  • ​Integrate interactive, physically based ray-marching volume rendering to visualize patient anatomy within the surgeon's view

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  • Provide diagnostic data from the headset to ensure electrical stability and optimal performance

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  • Track the surgeon's view angle and head rotation for reference and ergonomic feedback (to prevent neck strain, etc.)

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  • Design controls and control layouts for all color correction, view magnification, and mixing of real-world vs. virtual imagery

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  • Allow selection of preferred render styles and immersion modes, including AR, VR, and MR operating modes

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UI Design

Selected product screen layouts and control modules

(captured from a run-time demo session using anonymized DICOM data in lieu of a live patient)

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