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Zumio – Clitoral Stimulator

Design 1st Portfolio Zumio Case Study

Zumio - Clitoral Stimulator

World’s #1 Selling Oscillating Massager for Women

Turn Your Idea Into Reality

An Inside Glimpse Into the Product Design of Zumio

zumio concept sketches
zumio early stage concept sketch
zumio retail display kit
zumio tip prototypes
zumio product prototype build
zumio tip test prototype
zumio tip oscillate testing
zumio i-tip protective sleeve
Zumo electronic design test
zumio first volume quality
zumio model comparison
zumio types tips
zumio production packing
zumio product line award winning
zumio retail display stands
zumio wireless charger
zumio product packaging
zumio concept sketches
Zumio Concept Design Sketches

Product Design Requirements

Zumio came to Design 1st with an innovative idea to transfer energy using oscillation vs. vibration into the tip of an adult toy.
  • Refine concept, explore form, function and features
  • Be low-powered and quiet
  • 100% Waterproof
  • Simple adjustable controls with easy to change speeds

Engineering Challenges

Implementing Design 1st’s proven design and engineering process, the team was able to overcome several obstacles:
  • Design, engineer, and test a patented "SpiroTip" rotating motion technology, mimicking features of an electric toothbrush
  • Test dozens of tip designs to concentrate sensation
  • Balance battery power, weight, and cost
  • Rotate tip at speeds up to 7000 rpm with pulsing pressure at 300rpm without stalling the motor drive
zumio product prototype build
Product Prototypes for Testing
zumio-stimulator
Zumio won the prestigious A'Design Award

Product Results

Through creativity and technical understanding, the Design 1st team developed an award-winning product that:
  • Won the 2021 Adult Toy A'Design Award
  • Sold 250K+ units across the world
  • Expanded technology to four unique products
  • Received hundreds of mainstream press mentions (i.e. Vice, Cosmo, Oprah, Wired, NYT)
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Published on: May 26, 2023

vSculpt – Pelvic Floor Toning

Design 1st Portfolio Case Studies

vSculpt - Pelvic Floor Toning

World's First Pelvic Floor Rejuvenation Device Using Infrared Light

Turn Your Idea Into Reality

An Inside Glimpse Into the Product Development of Joylux's vSculpt

joylux vsculpt mock up prototype
joylux vsculpt 3d prototype; transparent parts disassembly
joylux vsculpt component parts
joylux vsculpt mfg plastic
joylux vsculpt prototype parts
joylux vsculpt electric circuit prototype
joylux vsculpt injection mold tool
joylux vsculpt waterproof test
joylux vsculpt electronic design; interior and exterior
joylux vsculpt ir light heat
Joylux Manufacturing 2 product unboxing design packaging
joylux vsculpt connected app mobile, photonic gel
joylux vsculpt mock up prototype
Early benchmodel form factor prototypes

Product Design Requirements

After spending two years developing the vSculpt, Joylux was nowhere close to manufacturing and launching the product. Joylux turned to Design 1st for help, asking for an aggressive 16-week timeline to get functional prototyping working.
  • Redesign the product structure and internal components for lower-cost and easier manufacturing​
  • Deliver a fully-functional prototype for user testing
  • Add bluetooth connectivity to interact with App
  • Design packaging and help set up volume manufacturing and support regulatory approvals

Design and Engineering Challenges

Implementing Design 1st’s proven process, the team was able to overcome several obstacles to achieve medical regulatory approval and strict quality controls.
  • Quickly identified engineering risks and opportunities to facilitate low-cost trial units in short timeframe
  • How to integrate the LEDs, heat and vibration technology into the ergonomic constraints of the industrial design targets
  • Build low-cost demo models to test first in the lab and then with users making sure 90% of the designed could be carried over for volume manufacturing
  • Use silicone overmodling to seal electronics and allow light transfer without energy loss
  • Waterproof testing and updating design based on user feedback that met medical device regulations
vSculpt Waterproof Testing
joylux vsculpt prototype parts
In-House Production Assembly

Product Results

Through creativity and technical understanding, the Design 1st team developed an award-winning product and helped Joylux secure over $15 Million in VC funding.
  • Achieved both FDA and Health Canada regulatory certifications.
  • On-going support of volume production runs to feed sales across six different countries
  • The vSculpt won multiple design awards and founder & CEO, Colette Courtion was named a FemTech leader
  • Joylux signed an exclusive partnership with Halle Berry's Respin brand focused on women's health
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Award-Winning medical device partners with Halle Berry to raise Menopause awareness.

“Design 1st understands getting high-quality products to the market quickly, while maintaining the user WOW factor. The Joylux team required an experienced, creative design-engineering team to guide us through the development and setup of our manufacturing. The Design 1st team was first class, they helped transform our technology and marketing goals into a world-class product to help women”

joylux-colette-cortion
Colette Courtion

CEO & Founder, Joylux

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Visit Joylux Website

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Published on: May 26, 2023

TravelWay – Lunch Box Container

Design 1st Portfolio Case Studies

TravelWay - Lunch Box Container

All-In-One lunch box container innovation

Turn Your Idea Into Reality

An Inside Glimpse Into the Development of TravelWay's Food Cube™

travelway foodcube ui concept
travelway foodcube concept mechanism; sketch
travelway foodcube concept mechanism 2
travelway foodcube concepts sketches
travelway foodcube 3d design
travelway foodcube engineer test
travelway foodcube 3d render
travelway foodcube dev process
travelway foodcube microwave test
travelway foodcube design challenge
travelway foodcube prototype test
travelway food cube final product; lunchbox
travelway foodcube concepts sketches
3D Concept Design

Product Design Requirements

Travelway Group came to Design 1st looking for help in developing a new line of unique innovative lunch containers to solve the common complaints associated with existing containers, including broken hinges and damage from microwave and dishwasher usage.
  • Develop a locking-lid with air-tight seal and slow-release hinge opening that can withstand the freezer, microwave, and dishwasher after repeat use.
  • Meet target product costs by develop multiple designs for review and test
  • Be simple-to-use, clean, and durable to withstand freezing and heating over and over.

Design and Engineering Challenges

After selecting a final design concept the engineering teams worked together on several hinge technologies that would survive the harsh environments of freezers, microwaves, and dishwashers through bench model build and test. 
  • Prototype and test the five main components: lid, gasket seal, elastic hinge loops, rotary damper hinge
  • Test multiple BPA and phthalate free materials with focus on the hinge design quality to ensure product reliability over extended use in variety of applications.
  • Test and finalize pre-production prototype to ensure consistent quality over high yield, (100,000 plus) volume production runs to meet order demand timelines.
travelway foodcube prototype test
Initial Design Prototype Test
travelway foodcube 3d render
Engineering Tests

Product Results

Through creativity and technical understanding, the Design 1st team developed an award-winning, innovative FoodCube.
  • Successful large volume 250000+ volume production run to meet strong consumer demand
  • Won the IDA and GrandPrix design awards for kitchen food products
  • Global distribution across multiple major retailers make FoodCube an industry-leading lunchbox device.
Get Free Consult

We went from product idea to 250,00 volume production in under twelve months

“Design 1st was the perfect partner fit to guide us through end-to-end development and manufacture, particularly as this was our first time taking on a fully custom product in this category”
Joe Assi

VP Sales, Travelway Inc.

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Published on: May 26, 2023

Toddler Monitor – Safety Door Sensor

Design 1st Portfolio Case Studies

Toddler Monitor - Safety Door Sensor

The World's Top Selling Toddler Monitor Device

Turn Your Idea Into Reality

An Inside Glimpse Into the Development of Toddler Monitor Door Sensor

toddler monitor early concept sketches
toddler monitor concept sketches
toddler monitor 3d build components interior
toddler monitor assembly prototype
toddler monitor prototype test build
toddler monitor proof of concept
toddler monitor mobile app
toddler monitor packaging
toddler monitor volume mfg manufacturing run; molds for device casing
toddler monitor context image; toddler with monitor device hanging off doorknob
toddler monitor concept sketches
Concept Sketches

Product Design Design Requirements

The Toddler Monitor co-founders came to Design 1st with a working prototype for a baby monitor and had ideas for the final design, however, needed a partner to help transform the Arduino –driven proof of concept into a child-friendly, low-cost connected device ready for mass production.

  • Friendly-design, warm, cute, safe for toddlers
  • Long-lasting battery and wireless connectivity
  • Connect to an App, and be easy to set up and use.

Engineering Challenges

Implementing Design 1st’s proven process, the team was able to overcome several obstacles to:
  • Meet the goal of having the battery, fully-charged, last up to five days with continuous usage
  • Maintain wireless connection in various home environments with concrete and multiple floors
  • Meet the target product cost by testing, and selecting the right mix of components and design configuration.
toddler monitor prototype test build
Early Prototype Testing
toddler monitor packaging
Toddler Monitor Packaging Contents

Product Results

Through creativity and technical understanding, the Design 1st team developed an award-winning product that:
  • Successful pitch on CBC's Dragon Den generated a $100,000 investment for 20% of the company.
  • Achieved rapid turnaround from concept to production in under nine months.
  • Landing over a dozen major retailers, and continues to be the top selling toddler monitor product in the world!
Get Free Consult

Award-Winning Product that went From Idea to fully manufactured in under 12 months

“We couldn’t have accomplished what we have without the end-to-end services and guidance that Is provided by this team. We lucked out in finding a great partner!”
krista-teare-lisa-caruso
Krista Teare and Lisa Caruso

Co-Founders, ToddlerMonitor Inc.

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Published on: May 25, 2023

thinkRF – RF Spectrum Analyzer

Design 1st Portfolio Case Studies

thinkRF - RF Spectrum Analyzer

Market disrupting 27 GHz spectrum analyzer

Turn Your Idea Into Reality
ThinkRF Market disrupting spectrum analyzer Case Study

An Inside Glimpse Into the Product Development of ThinkRF's Spectrum Analyzer

thinkrf 3d design modular
thinkrf modular design concept 3d; multiple thinkrf in a modular setup
thinkrf preproduction part with screw holes and ridges
Thinkrf engineering circuitry
thinkrf thermal analysis revealing mostly cool temperatures
thinkrf airflow table analysis
thinkrf wall mount bracket
thinkrf volume mfg product manufacturing
Think RF Context office space with multiple thinkrf setup on a cubicle wall
thinkrf modular design concept 3d; multiple thinkrf in a modular setup
Virtual concept renderings of Think RF enclosure design

Background & Design Requirements

ThinkRF came to Design 1st to develop a robust heat-dissipating enclosure that would both safely hold the custom electronics and create a unique, branded design.
  • Develop multiple design concepts, including a modular stacking frame
  • Meet regulatory standards and dissipate heat to prevent any thermal issues during usage
  • Create a low-volume run of functional prototypes for user testing in real environments

Engineering Challenges

Implementing Design 1st’s proven product development process, the team overcame several obstacles to deliver the industry-leading spectrum analyzer device.
  • Develop an optimized heatsink enclosure design to maintain required device operating temperature
  • Build a virtual 3D model for simulation testing to understand wireless, heat, and air flow properties
  • Built multiple design concepts using CNC Machining for real-world user testing of the device
thinkrf preproduction part with screw holes and ridges
CNC machined enclosure prototype for Think RF
thinkrf volume mfg product manufacturing
Bench model testing of PCB geometry for enclosure design

Product Design Results

Through creativity and technical understanding, the Design 1st team developed an award-winning product that continues to be the #1 global selling spectrum analyzer.
  • Develop and test a fully functioning unit in under six weeks to exploit market opportunity.
  • Mount the custom PCB’ s on heat spreader plates cooled by thermal convection.
  • Develop multiple variants of RF cable connector design to optimize user experience.
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Published on: May 25, 2023

TabloTV – OTA DVR for Cordcutters

Design 1st Portfolio Case Studies

TabloTV - OTA DVR for Cordcutters

Disruptive over-the-air DVR that shook up the TV cord cutting industry.

Turn Your Idea Into Reality
tablotv market ready product with box and app for phone, tablet, laptop, and tv

An Inside Glimpse Into the Product Design of TabloTV's Over-the-Air DVR

TabloTV concepts 3d
Tablo design 3; sleek black rectangular box design
Tablo design engineering; 3d interior
Tablo manufacturing parts
tablo product design process
Tablo Prototyping; holding physical prototype Tablo box
tablotv electronics design
tablo tv app; UI showing live tv, recordings, tv shows, movies, sports, scheduled
tablotv thermal analysis results
tablotv fea thermal analysis
tablotv context photo; man sitting in living room using TabloTV to watch show or movie
TabloTV concepts 3d
TabloTV 3D Concept Ideas

Product Design Requirements

TabloTV chose Design 1st to transform their innovative DVR technology into an elegant design enclosure that would deal with the high heat output from advanced chipsets and stand out.
  • Develop multiple design concepts of the enclosure
  • Be low-powered and quiet.
  • Be simple-to-use and easy-to-install.
  • Understand and prevent thermal issues over extended usage

Engineering Challenges

The primary engineering challenge was how to alleviate thermal issues while maintaining a sleek, compact form factor.
  • Explore and test different forms with the integration of a silent, passive heatsink.
  • Build a 3D CAD virtual model to run FEA thermal simulations to understand heat and air flow during operation.
  • Build multiple benchmodel prototypes for testing.
Tablo manufacturing parts
Manufacturing Parts Assembly
Tablo design engineering; 3d interior
3D Engineering Design

Product Results

The six-month product development project resulted in a pre-production prototype ready for market launch at CES (Consumer Electronics Show) in Las Vegas.
  • TabloTV acquired for $14 Million by Scripps in 2023
  • Recognized by Forbes as one of the top ten companies reinventing the TV Industry
  • TabloTV built a passionate group of cord-cutting consumers with global distribution and continues to thrive today
  • Visit: www.tablotv.com to learn more
Get Free Consult

Award-Winning Product Acquired for $14M by Scripps

“Design 1st had the expertise to turn a concept into a unique branded look and marketable product that met our high expectations. “

Grant Hall

Founder and CEO, TabloTV

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Published on: May 24, 2023

Stanley – Pediatric Protection Bracelet

Design 1st Portfolio Case Studies

Stanley - Pediatric Protection Bracelet

RFID protection bracelet locates pediatric patients and long-term care residents

Turn Your Idea Into Reality
pedz-feature-image

An Inside Glimpse Into the Product Development of Stanley's Pedz Bracelet

pedz concept design sketches
pedz manufacturing 3D parts
Pedz physical prototype assembly
pedz 3d opened showing inside engineering
pedz-army-design
hugs-pedz-baby
pedz concept design sketches
Concept Design Sketches

Product Design Requirements

Stanley Healthcare came to Design 1st for help with a new product concept. The requirement was to design a bracelet for tamperproof security, quick removal, and easy reattachment. Stanley required full product development support from concept design through to manufacturing.
  • Low-cost replaceable brands on bracelets to support consumable revenue
  • Design, engineer, and test the RFID connection for secure usage within hospital environments
  • Develop a fully-functional prototype for clinical trials within a hospital environment

Engineering Challenges

Implementing Design 1st’s proven process, the team overcame several obstacles to bring the final RFID bracelet design to volume manufacturing.
  • Electronic design and testing of the RFID 2.4Ghz connection in a variety of environments
  • Low-cost manufacturing that would support multiple colors and designs for the bracelet electronic device
  • Several rounds of prototyping to finalize the easy-to-attach, comfortable and secure final design
Pedz physical prototype assembly
Prototype Assembly
Portable Wireless Bracelets with Multiple Benefits

Product Results

Through creativity and technical understanding, the Design 1st team successfully developed the Pedz™ Tag into a wireless medical security device to protect patients.
  • Device continues to be the #1 selling patient security bracelet for over 10 years
  • Achieved rapid turnaround from concept to clinical trial testing in under one year
  • Securitas acquired Stanley Healthcare and continues to market and sell PedZ globally
Get Free Consult

Transforming an innovative RFID secure bracelet concept into a manufacture-ready device

“Two end users had to be accommodated – the individuals who wear the tags and the healthcare providers who use our systems. Design 1st did a superb job of balancing the end user requirements of both our products. We needed both devices to be durable and secure as well as easy-to-use, while still being attractive and comfortable to the individual patients.”
Kevin Smith

Product Manager, Stanley HealthCare

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SoloRolo – Myofascial Release Ball

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SoloRolo - Myofascial Release Ball

Therapeutic Tool for Myofascial Release and Trigger Massage

Turn Your Idea Into Reality
SoloRolo Context 3; woman using solorolo on her lower back against the wall in the gym

An Inside Glimpse Into the Development of SoloRolo's Myofascial Release Ball

SoloRolo early Design sketches
solorolo final design concept 3D drawing
SoloRolo Engineering; 3D parts breakdown overview
SoloRolo Prototype; physical prototype being demonstrated by man
solorolo retail packaging box design
solorolo packaging design
SoloRolo Manufactured parts
solorolo physical prototype testing
solorolo benchmodel prototype
SoloRolo Context 1; man positioned on a bench in gym uses solorolo to massage his lower calf
SoloRolo Context 2; woman using solorolo to massage her back against the wall in the gym
SoloRolo Hero1
SoloRolo early Design sketches
Initial SoloRolo design sketch

Product Design Requirements

Physiotherapist, John Pathrose, came to Design 1st with a product idea for a self-massage tool to help with trigger point massage to alleviate pain. John required full product development support, including design, engineering, prototyping, packaging, and manufacturing setup.
  • Develop several concepts to find the best design
  • Goal was to replace the tennis ball massage technique with a more effective and easier-to-use device
  • Build a fully functional prototype for user testing

Engineering Challenges

After choosing a design direction, the Design 1st team began detailed engineering to define the materials, size, components, and manufacturing method. This process unrevealed several tough design challenges.
  • Research into human factors of myofascial release to understand the correct one-size-fits-all geometry
  • Revise device design to lower manufacturing costs
  • Several rounds of bench-model prototyping
SoloRolo Manufactured parts
Prototype housing for product testing
solorolo retail packaging box design
Packaging of final product ready for market

Product Results

Through creativity and technical understanding, the Design 1st team developed an award-winning product that:
  • Launched successfully to market with strong reviews from both consumers and physiotherapists
  • Achieved rapid turnaround from concept to volume production in under one year
  • Continues to be the #1 top selling myofascial release tool on the market today
Get Free Consult

From concept idea to the #1 selling myofascial release tool on the market in under one year!

“Design 1st’s designers and engineers demonstrated the right creativity and technical understanding, managing the entire product design process from idea to manufacturing.”

John Pathose
Inventor and Founder, Solorolo Inc
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Published on: May 23, 2023

Rumidifier – Zero Energy Humidifier

Design 1st Portfolio Case Studies

Rumidifier - Zero Energy Room Humidifier

Eco-Friendly, Zero Energy Home Humidifier Went From Idea to 500K Units Sold

Turn Your Idea Into Reality

An Inside Glimpse Into the Development of Rumidifier's Zero Energy Humidifier

rumidifier napkin sketches
rumidifier 3d cad bom parts with water containers, top housing, filter, and bottom housing
Rumidifier 3D concept design ideas
rumidifier 3d cad rendering
Rumidifier barebones physical prototype
Rumidifier prototype part zoomed in
rumidifier prototype parts
Rumidifier 3D concept design ideas
3D Concept Design Variations of Rumidifier

Product Design Requirements

Rumidifier came to Design 1st with a napkin sketch idea to design a zero-energy humidifier device with no moving parts that would sit on top of household forced air vents.
  • Use a furnace air vent to humidify home without any external power source
  • Design and test multiple concepts to get the optimal materials, form factor, and water reservoirs
  • Be simple-to-use and easy-to-install.

Design and Engineering Challenges

The biggest engineering challenge for the design team was maintaining the airflow from the register while placing a moist object in front of the register vent. 
  • Two rounds of prototyping were carried out to test the water flow rates, wicking, airflow, vent sizing and the overall size and appearance of unit
  • Selection of a good wicking material that would absorb water up to 10 inches high allowed for a simple bowl approach to the water system
  • Understanding the behavior of air flow in smaller and larger vents in homes across North America
Rumidifier barebones physical prototype
Early Physical Prototype
rumidifier-product
Exploded View of Rumidifier Product

Product Results

Through creativity and technical understanding, the Design 1st team helped Rumidifer go from an idea to an award-winning innovative product that has sold over 1 Million units across North America and continues to grow.
  • Rumidifier was featured on the Dragons Den and signed a lucrative investment deal
  • Rumidifier secured multiple major retail store contracts with Home Depot, Canadian Tire, Costco etc.
  • You can buy Rumidifier at www.rumidifier.com
Get Free Consult

One Stop Shop From Product Idea to Manufacturing and Store Shelves

“I needed to transform the Rumidifier napkin sketch design into a working prototype and then a real product. As a first time inventor, the importance of having a knowledgeable business-focussed product development partner like Design 1st, is very clear to me now.”
Jeri Rodrigs

Founder and CEO, Rumidifier 

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Published on: May 23, 2023

Quirklogic – Enterprise Connected Whiteboard

Design 1st Portfolio Case Studies

QuirkLogic - Enterprise Connected eWriter

The World's Largest E-Ink Digital Whiteboard

Turn Your Idea Into Reality

An Inside Glimpse Into the Development of QuirkLogic's eWriter

ergonomic design testing; woman testing multiple whiteboard designs
injection mold ready; metal container for molding
injection mold tool; molding tool being lifted
prototype; assembling quirklogic prototype pieces
multi screen e-ink boards
production unit; quirklogic four vertical multiscreens in a row being used in a presentation
packaging production; quirklogic cardboard box packaging with marker sketches design
e-ink whiteboard context; woman using quirklogic whiteboard in a presentation meeting
QuirkLogic Concept Design Testing

Background & Design Requirements

QuirkLogic came to Design 1st looking for help to transform their concept of an e-ink whiteboard from a scale model prototype into a 4ft. tall interactive touch surface.
  • Replicate a pen-to-paper user experience
  • Wall-mountable, portable, light-weigh, wifi-enabled, modular, and use e-ink technology
  • Create the functionality of a traditional paper flip chart in a digital e-ink format

Design and Engineering Challenges

Implementing Design 1st’s proven product development process, the team was able to identify, test, and remove major product risks and deliver a functional prototype.
  • Structural honeycomb layers provided flex resistance strength while the aluminum rails add protection
  • During design of quick disconnect system, multiple rounds of user testing were done to achieve balance between form and function.
  • Explore rigid panel architectural construction, commonly used in marine applications for weight and strength
  • The only hiccup was the side rail parts were warping due to heat during molding. Design 1st fixed the issue with a cooling jig for use during assembly.
E-Ink Prototype Whiteboard Assembly
QuirkLogic Multi-Screen Setup

Product Results

Through creativity and technical understanding, the Design 1st team developed an award-winning product for QuirkLogic, that received accolades for being the largest, commercial e-ink display in the world!
  • A custom manufacturing process was set up and refined to perfect the final product assembly process during volume production.
  • Quirk's e-ink display is the world's largest by a factor of 10 and the micro-thin glass with touch overlay makes replication difficult
  • Optimized screen flex tolerance, cable management and mechanics of the quick disconnect system
  • QuirkLogic won multiple awards include Deloitte Top 40 Tech, InfoComm iAward Winner, and A-Design Award
Get Free Consult

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Published on: May 23, 2023