Email a Question
Talk to us
Get free consult

Archives: Portfolio

Description.

QNX – Connected Concept Car

Design 1st Portfolio Case Studies

QNX - Connected Concept Car

Cutting-edge concept car wins CES “Design and Engineering Showcase" award

Turn Your Idea Into Reality
qnx engineering; man sat on the drivers seat of the qnx car showing the dashboard and high-tech touchscreen

An Inside Glimpse Into the Development of QNX's Connected Concept Car

dashboard rebuild prep; spread out on the table are car dashboard parts
QNX Prototype; man inserting car interior prototype parts
custom parts containing electronics with electric sockets
QNX Sewing; sewing leather parts with white thread
qnx concept car build interior
qnx bench model testing; team runs tests of the touchscreen on the dashboard
QNX Concept screen in the car
qnx engineering; man sat on the drivers seat of the qnx car showing the dashboard and high-tech touchscreen
concept car ready man presenting GNX sign on car door
QNX Concept screen in the car
QNX Bentley Concept Design

Background & Design Requirements

QNX Software (owned by Blackberry) came to Design 1st wanting to showcase their car infotainment technology at CES (Consumer Electronics Show). QNX needed support integrating an innovative display into a brand-new Bentley.

  • Match the leather stitching of the Bentley, making the display integration seem natural.
  • Add wireless connectivity and power to operate the interactive display screen
  • Meet a aggressive six month timeline to deliver car to CES on time

Design and Engineering Challenges

Implementing Design 1st’s proven process, the team was able to overcome several obstacles to:
  • Take apart the entire dashboard, and integrate the display with a seamless look and feel.
  • Build a virtual 3D model of the dashboard and design custom 3D-printed parts to house the display
  • Work with QNX to power up and configure the software and sensors to give for driver interaction.
QNX Prototype; man inserting car interior prototype parts
Complete disassembly of the Bentley dashboard
qnx bench model testing; team runs tests of the touchscreen on the dashboard
QNX Test Engineering

Product Results

Through creativity and technical understanding, the Design 1st team developed an award-winning product that:
  • Meet timeline and helped QNX deliver the project car to CES on time and fully functioning
  • The QNX car received praise from dozens of major media publications and car manufacturers
  • QNX is now one of the global-leading brands for car infotainment systems
Get Free Consult

Related Case Studies

Published on: May 23, 2023

Prodrive Systems – Dental Drill

Design 1st Portfolio Case Studies

ProDrive Systems - Dental Drill

ProDrive Universal High-Speed Dental Drill System

Turn Your Idea Into Reality

An Inside Glimpse Into the Development of ProDrive's Dental Drill

dental drill bit sketches
eng test force
dental drill piece
fea dental drill c
parts
prototype testing
Prodrive Design
manufacture volume production
dental drill innovation
dental drill bits
Prodrive Engineering
dental innovation team
dental drill innovation showcase quote
Prodrive Engineering
Exploded View of High Speed Drill Components

Background & Design Requirements

ProDrive Systems came to Design 1st with innovative methods to disrupt the traditional high-speed drill and needed help to finalize the design and bring the device to market.
  • Finalize design of a triangular bur shank to replace the friction fit of traditional dental drills
  • Be low-powered and quiet, and meet FCC and Health Canada regulations for dental equipment
  • Can be used with existing dental handpieces

Engineering Challenges

By following a rigorous medical development process with prototype and testing, the team overcame several tough technical challenges:
  • Develop test equipment to compare ProDrive dental drill to traditional methods for accuracy, speed and durability
  • Prototype and test the innovative turbine assembly where the chuck locks around the triangular bur
  • Update original design to allow for extending and locking the triangular bur for variable length cutting
parts
High Tolerance Machined Parts for testing variety of handpieces
Production Turbines were produced for all major handpiece brands

Product Results

The Design 1st team helped ProDrive develop and manufacture a disruptive tool for the dentist industry that delivers superior hand piece performance, accuracy and increased cutting speed, improving the overall experience for both patients and dentists.
  • Developed test equipment to compare in the leading market hand pieces and conducted field tests with dentists across North America
  • Design robust enough to be launched internationally with ambition to be industry standard within five years
  • Won multiple awards for innovative dentistry products, and named a Top 10 Life Sciences Company
Get Free Consult

Disruptive dental drill innovative moved from concept to volume manufacturing

“Design 1st’s considerable design expertise and manufacturing knowledge allowed us to completely outsource our development and their one stop expertise helped us become the leading dental technology company revolutionizing our industry.”
Richard St-Pierre

President and CEO, ProDrive Systems

Get Free Consult

Related Case Studies

Published on: May 19, 2023

SanDisk – Enterprise SSD Device

Design 1st Portfolio Case Studies

SanDisk - Enterprise SSD Device

Revolutionary enterprise server SSD device sold to SanDisk for $327M

Turn Your Idea Into Reality
enterprise ssd render concept

An Inside Glimpse Into the Product Development of SanDisk's Enterprise SSD

qa mfg tolerance sp
concept ssd
3d cad ssd stack
exploded bom 3dcad
sla prototype parts
machine part prototype
parts
dental drill innovation
benchmodel testing
prototype testing
manufacture volume production
pre production prototype
production install
enterprise ssd mfg
sla prototype parts
SLA Rapid Prototype Parts for assembly, parts fit and DFM

Product Design Requirements

Pliant Technology came to Design 1st with innovative SSD technology and required a unique enclosure that would alleviate thermal issues, distinguish the brand, and be cost-effective for volume manufacturing.
  • Design several new enclosure concepts that would prevent thermal heat issues and match the brand
  • Integration of heat sensitive electronics in an ultra-compact shape that maintains precise flexing characteristics
  • Develop a pre-production prototype for user testing and support manufacturing setup for volume production

Engineering Challenges

Pliant Technologies’ innovative approach to SSD packed a lot of power into a small enclosure, to ensure the product would not fail required several rounds of prototyping and virtual simulations to understand heat issues.
  • Develop an optimized heat sink design for enclosure
  • Rapid design, build and test of bench model prototypes to determine optimal form factor for heat dissipation
  • Build several SLA prototypes to test concept designs before choosing a final design direction
machine part prototype
CNC Machined Prototype of External Housing for thermal tests
enterprise ssd mfg
First Volume Production 2.5 inch SSD drive

Product Results

The success of Pliant Technologies’ SSD was recognized by SanDisk, and the entire company and product line were acquired for $327M.
  • High quality production process and enclosure design built trust with enterprise users
  • Achieved rapid turnaround from concept to production in under 6 months.
  • Minimum component count and ease of assembly of the cast metal enclosure were critical to high quality volume production over multiple manufacturing runs
Get Free Consult

Solved a tough technical challenge and brought us to successful volume manufacturing in nine months

“We highly valued Design 1st as our product development partner. Their design and engineering expertise was exactly what we needed to be successful.”
Mike Chenery

CEO, Pliant Technologies Inc
Senior Partner, SanDisk

Get Free Consult

Related Case Studies

rendering

Design 1st Portfolio Case Studies Fantasy – Connected Scoreboards...

View More
urban wi-fi-use

Design 1st Portfolio Case Studies Belair Networks – Urban...

View More
cloud-9-trader-VOIP-device

Design 1st Portfolio Cloud9 Case Study Cloud9 Technologies A...

View More
connected-personal-security-device

Design 1st Portfolio Case Studies Endrelia – Watchdog Wearable...

View More
liberty-pumps-nighteye-sump-pump

Design 1st Resources Case Studies Liberty Pumps – NightEye™...

View More
senior-care-voice-assistant
Lifepod – Caregiver Voice Assistant

Design 1st Portfolio Case Studies Lifepod – Voice Enhanced...

View More

Published on: May 19, 2023

Pannexx – Portable Solar Trailer

Design 1st Portfolio Case Studies

Pannexx - Portable Solar Trailer

Telescoping Trailer Mounted Portable Solar Light Tower

Turn Your Idea Into Reality
design

An Inside Glimpse Into the Development of Pannexx's Portable Solar Trailer

3d cad shipping stac
solar trailer 3d cad
collasped solar trailer
prototype
solar trailer production
product launch event
manufacture
in field
solar trailer 3d cad
3D CAD Rendering

Background & Design Requirements

Pannexx chose Design 1st to integrate existing solar technology onto a commercial-grade trailer to create a mobile solar-powered light tower for municipalities to use in construction and road maintenance events.
  • Use existing off-the-shelf (OTS) trailers that meet highway safety regulations.
  • Create a virtual 3D model for simulation testing before building bench model prototypes.
  • Develop user-friendly design for setup and travel.

Design and Engineering Challenges

Implementing Design 1st’s proven process, the team was able to overcome several obstacles to:
  • Optimize design for light coverage and battery usage.
  • Run multiple virtual simulations to understand weight distribution, assembly process, and air flow during travel
  • Build a fully-functional machined prototype for testing.
  • Meet highway safety regulations for trailers
prototype
Prototype Frame Assembly Fine Tuning
manufacture
First Unit Production according to Specs and CAD Design

Product Results

Through creativity and technical understanding, the Design 1st team developed a production-ready device:
  • Won multiple large government contracts for portable solar power generation units.
  • Achieved rapid turnaround from concept to production in under nine months.
  • Design 1st continues to support Pannex with ongoing manufacturing of solar trailer products.
Get Free Consult

Related Case Studies

Published on: March 31, 2023

Nuraleve – Neuromodulation Pain Therapy

Design 1st Portfolio Case Studies

Nuraleve - Neuromodulation Pain Therapy

Revolutionary Pain and Addiction Therapy Using Neuromodulation

Turn Your Idea Into Reality
Hero

An Inside Glimpse Into the Development of Nuraleve's SmartStim for Cravings™

Concept
keypad color design
Test
infection molding
ENG
Prototype
ui testing
Manufacture
Concept
Concept Sketches of Table Top Device With User Interface

Background & Design Requirements

Nuraleve came to Design 1st to transform their innovative neuromodulation headband technology into a manufacturable medical device for clinical use of pain and addiction therapy. Design requirements included:
  • Develop an MVP prototype for informal testing and clinical trials
  • Comfortable one-size fits all headband with integrated electronic sensors in precise locations.
  • Base unit with intuitive user-interface design

Industrial Design Challenges

Implementing Design 1st’s proven process, the team was able to overcome several obstacles to:
  • Develop a one-size fits all headband through multiple user testing of prototypes with various materials.
  • Meet all medical regulatory requirements to accelerate Health Canada and FDA approval
  • Design a volume production unit, to optimize material and shipping costs.
Prototype
Product Prototype - Custom user interface, display and integrated electronics
ENG
First Volume Production Run Part Inspection

Results

Through creativity and technical understanding, the Design 1st team developed an innovative medical device:
  • Fully-functional pre-production prototype ready for clinical testing in under twelve months.
  • Positive user feedback from both patients and medical professionals.
  • Successful first volume production run that met ISO 9001 and ISO 13485 medical device regulatory approval
Get Free Consult

Revolutionary medical device technology for pain and addiction therapy using neuromodulation.

“We came to Design 1st with an ugly black box and knew we needed a better solution. Design 1st came through and gave us ideas we never thought possible that exceeded our expectations.”
nuraleve-mathieu lemay
Matthew Lemay

VP of Service Delivery, Nuraleve

Get Free Consult

Related Case Studies

rendering

Design 1st Portfolio Case Studies Fantasy – Connected Scoreboards...

View More
urban wi-fi-use

Design 1st Portfolio Case Studies Belair Networks – Urban...

View More
cloud-9-trader-VOIP-device

Design 1st Portfolio Cloud9 Case Study Cloud9 Technologies A...

View More
connected-personal-security-device

Design 1st Portfolio Case Studies Endrelia – Watchdog Wearable...

View More
liberty-pumps-nighteye-sump-pump

Design 1st Resources Case Studies Liberty Pumps – NightEye™...

View More
senior-care-voice-assistant
Lifepod – Caregiver Voice Assistant

Design 1st Portfolio Case Studies Lifepod – Voice Enhanced...

View More

Published on: March 31, 2023

NorthVu – HDTV Fractal Antenna

Design 1st Portfolio Case Studies

NorthVu - HDTV Fractal Antenna

HDTV Fractal Digital Antenna for Over-the-Air Television

Turn Your Idea Into Reality
Hero

An Inside Glimpse Into the Development of NorthVu's HDTV Fractal Antenna

Design
3d concept form
3d cad exploded view
fractal hdtv electr
Prototyping
Engineering
northvu-ota-antenna-production
shipping optimization
final packaging
Design
Early Concept Sketches

Background & Design Requirements

The client came to Design 1st with innovative fractal technology to capture over-the-air television signals and wanted to develop a production-ready consumer device to sell in twelve months. Design requirements included:
  • Unobtrusive design that would seamlessly blend into consumer home entertainment environments
  • Optimized design with packaging for mass production
  • Create a functional prototype for lab testing

Product Design Challenges

Implementing Design 1st’s proven process, the team was able to overcome several obstacles to:
  • Create a proof-of-concept prototype using NorthVu's existing fractal technology with a 40Km range
  • Build a virtual 3D model for thermal FEA simulations to ensure product quality over long-term
  • Optimize packaging for costs and pallet shipping
Engineering
Proof of Concept Electronics Prototype Testing
northvu-ota-antenna-production
Electrical Wiring

Product Results

Through creativity and technical understanding, the NorthVu antenna became one of the top selling OTA (Over-the-air) antennas to capture free television signals in North America:
  • Commercially successful partnership with NXP Semiconductor using their RF technology.
  • Achieved rapid turnaround from concept to regulatory approval and volume production in fourteen months.
  • NorthVu signed multiple distribution agreements with major retailers to become North America's top-selling OTA antenna in the indoor category.
Get Free Consult

North America's first commercially available indoor digital OTA (over-the-air) television antenna

“Design 1st delivered an ultra-compact, elegant and reliable enclosure and retail shelf packaging that will capture the attention of consumers and prospective partners. We are confident in outsourcing our requirements to Design 1st when we need them.”
northvu-spenser-williams
Spenser Williams

CEO,  NorthVu Systems Ltd.

Get Free Consult

Related Case Studies

Published on: March 31, 2023

Neptec – 3D LiDAR Sensor

Design 1st Portfolio Case Studies

Neptec - 3D LiDAR Sensor

Extreme Condition 3D LiDAR Obstacle Detection

Turn Your Idea Into Reality
Hero

An Inside Glimpse Into the Development of Neptec's 3D LiDAR Sensor

concept review
electronic design concept
lidar mech design
lidar feature overview
build prototype
benchmodel prototype
alpha prototype test
3D Cad testing
electronic design concept
Electronic Design Concept

Background & Design Requirements

Neptec reached out to Design 1st to integrate their custom PCBs and 3D LiDAR technology into a rugged housing that would withstand the world’s harshest working environments during operation. Design requirements included:

  • 360 visual field of view for 3D LiDAR sensors.
  • Volume production ready design in ten months
  • Build a full functional alpha prototype for testing

Engineering Challenges

Implementing Design 1st’s proven process, the team was able to overcome several obstacles to:
  • Create fast prototype mock-ups to identify fit, function, and form issues early on.
  • Build 3D virtual model "digital twin" of device for FEA simulations on design concepts to review any thermal issues with air flow and internal heat.
  • Create bench-model engineering prototype for Neptec to run early-stage lab testing
alpha prototype test
Functional Prototype Early Stage Lab Test
3D Cad testing
Simulations of FOV on Machine Mounting Locations

Project Results

Through creativity and technical understanding, the Design 1st team developed Neptec’s flagship product:
  • Neptec Design Group was acquired by Maxar Technologies in 2018 for $42 Million.
  • Achieved rapid turnaround from concept to production units for in-field testing and use in thirteen months.
  • The design passed all regulatory certifications and remains the most rugged 3D LiDAR devices in the industry
Get Free Consult

Neptec Acquired by Maxar Technologies for $42 Million

“We needed an up and running engineering team and we needed them right away. We found that Design 1st had a lot of interesting ideas and paths that we probably wouldn’t have thought of because they have rugged electronics experience.”
neptec-derek-butler
Derek Butler

Director of Engineering, Neptec Technologies

Get Free Consult

Related Case Studies

Published on: March 31, 2023

Nanometrics – Seismic Monitoring Device

Design 1st Portfolio Case Studies

Nanometrics - Seismic Monitoring Device

Seismic Accelerometer designed for Rugged and Difficult Environments

Turn Your Idea Into Reality
Hero

An Inside Glimpse Into the Development of Nanometric's Seismic Monitoring Device

Design
3d concept
prod21
Prototype
benchmodel prototype
Engineer
Manufacture
Design
Product Design Sketches

Background & Design Requirements

Nanometrics engaged Design 1st for their industrial design and low-cost plastics injection molding expertise to design the rugged Titan – a triaxial accelerometer seismic monitor.
  • Extreme environment rugged, waterproof design
  • Match brand styling of Nanometrics existing devices
  • Intuitive and easy to set up for first-time users.
  • Utilize existing manufacturing processes

Design and Engineering Challenges

Implementing Design 1st’s proven process, the team was able to overcome several obstacles to:
  • Develop an optimized through FEA analysis to minimize thermal heat issues
  • Several rounds of prototype testing to ensure device is vibration-proof, and ruggedized for all environments
  • Use Nanometrics predefined PCB geometry as a constraint to the device housing size
Prototype
Prototype Housing
Manufacture
Nanometrics - Titan Accelerometer

Product Results

After nine months of product development, prototyping, and testing, Nanometric’s newest innovation “Titan” was ready for volume manufacturing.

  • The device easily passed all regulatory certifications
  • Achieved rapid turnaround from concept to production in under nine months.
  • Industry-leading seismic monitoring device used across the globe to measure seismic activity.
Get Free Consult

Related Case Studies

Published on: March 31, 2023

MyTrak – Smart Fitness Monitor

Design 1st Portfolio Case Studies

MyTrak - Smart Fitness Monitor

Award-winning wearable fitness monitor acquired by Curves®

Turn Your Idea Into Reality
feature image

An Inside Glimpse Into the Product Development of MyTrak's Slimcoach™

design concept
exploded 3d model
prototype
wearable testing
tracker bench test
fea analysis
production prototype
Electronics
Light Ring
finalrender concept
design concept
Concept Sketches

Background & Design Requirements

The client came to Design 1st wanting to transform the concept of a detachable clip-based wearable activity tracker with visual cues into a high-volume manufacturable product.
  • Provide visual cues to user on real-time activity.
  • Durable, detachable attachment mechanism for tracker
  • Slim design profile with three discrete buttons
  • Sensors to track movement and heart rate

Design and Engineering Challenges

Implementing Design 1st’s proven process, the team was able to overcome several obstacles to balance the design requirements with long-lasting performance.
  • Testing of multiple plastics and features to achieve a durable clip that can be easily detached from device
  • Battery selection to achieve 16-hour life, with size that would be meet the required slim profile design
  • Selection of annular light pipe to spread beams evenly for real-time visual interaction during fitness activity
exploded 3d model
3D CAD Exploded View
fea analysis
FEA Engineering Test

Product Testing: Issue Found

During pre-production prototype testing the material of the poly-carbonate material chosen for the detachable clip began creating problems and failing.
  • Users testing the device found it was difficult to detach due to friction, resulting in some devices breaking.
  • But by adding a lubricating compound called Lubriloy™ to the plastic, the clip attachment worked smoothly
  • A small low-volume production run and user test confirmed the additive lubricant fixed the issue

Product Results and Client Success

MyTrak transformed a concept idea into one of the world’s first mass-consumer fitness trackers on the market leading to an acquisition by Curves®

  • Following acquisition by Curves®, the SlimCoach was featured on the Biggest Loser® TV series
  • MyTrak successfully scaled volume production to hundreds of thousands of units with minimal issues
  • Successfully acquisition and transfer manufacturing files and setup to Curves®
mytrak-biggest-loser-tracke
Product Unit
Get Free Consult

Moving from concept to industry-leading fitness tracker and acquisition by Curves® in five years

“The Design 1st team’s ability to diagnosis, solve and execute on multiple design challenges throughout the product development was the key to the Slimcoach’s success in the marketplace”
mytak-reed-hanoun
Reed Hanoun

CEO and Founder, MyTrak Inc.

Get Free Consult

Related Case Studies

senior-care-voice-assistant
Lifepod – Caregiver Voice Assistant

Design 1st Portfolio Case Studies Lifepod – Voice Enhanced...

View More
Calibre Biometrics
Calibre Bio – Wearable Breath Tracker

Design 1st Resources Case Studies Calibre Biometrics World’s First...

View More
Prototype-Casings

Design 1st Resources Case Studies Momentum IoT: Eagle 1...

View More

Published on: March 31, 2023

Modgarden – Indoor Smart Gardening

Design 1st Portfolio Case Studies

Modgarden - Indoor Smart Gardening

IoT Connected Modular Urban Gardening System

Turn Your Idea Into Reality
modgarden-tiny-farm-product

An Inside Glimpse Into the Product Development of Modgarden's Indoor Smart Garden

concept photo
wood finish render
indoor grow overview
early concept
modular top concept
micro farm render
wiring schematic
prototype test
alpha prototype
seed packaging
app dev mockup
bill of material
modgarden-light-on-prototyp
concept photo
Concept Design for Modular Growth Units

Product Design Requirements

Tiny Farm approached Design 1st with a proof-of-concept prototype for a modular indoor gardening system and list of new design requirements. The idea was simple: create a connected indoor gardening system for health-conscious urban dwellers that could be monitored from a smartphone anywhere in the world.

  • Make this system modular and reproduce outdoor soil, light, and water conditions inside
  • Integrate sensors for monitoring light, humidity, temperature and water that sync with a phone app
  • Correct size and soil conditions to grow over a dozen types of "micro-greens"

Design and Engineering Challenges

Implementing Design 1st’s proven process, the team was able to overcome several obstacles to:
  • Conduct early-stage testing to replicate humidity, light, soil, and water conditions within an indoor environment.
  • Testing of breathable wicking material to optimize water uptake and retention.
  • Simplify electronics by developing an all-in-one modular sensor solution.
micro farm render
3D CAD and Product Architecture
app dev mockup
UI Design for Mobile App Feedback

Product Concept Results

Through creativity and technical understanding, the Design 1st team developed an award-winning product that:
  • Built fully-functional prototype with connected phone app to test multiple growing conditions and materials
  • ModGarden partner with Dalhousie University for soil feature and got multiple mainstream media mentions
  • Setup custom global supply chain for manufacturing, assembly, and logistic support
Get Free Consult

Move from product concept idea to fully-function prototype in 9 months

“The breadth of expertise Design 1st has in-house to experiment with configurations and sensors data use helped transform my vision into reality.”
Aamar Khwaja
Founder, Modgarden Inc.
Get Free Consult

Related Case Studies

senior-care-voice-assistant
Lifepod – Caregiver Voice Assistant

Design 1st Portfolio Case Studies Lifepod – Voice Enhanced...

View More
Calibre Biometrics
Calibre Bio – Wearable Breath Tracker

Design 1st Resources Case Studies Calibre Biometrics World’s First...

View More
J2-Design

Design 1st Resources Case Studies J2 Lights Low-Energy Commercial...

View More
Prototype-Casings

Design 1st Resources Case Studies Momentum IoT: Eagle 1...

View More

Published on: March 30, 2023