In this episode, we meet with a guest who has led engineering teams for brands such as Nerf, SuperSoaker, PlayDoh, Baby Alive, FurReal, and more.

Kevin Dakan grew up outside of New York City. He had a passion for tinkering that started early when he would play with Transformers and then go home to make them out of Legos. He went to school in Buffalo, New York where he completed his degree in mechanical engineering. His first job out of school was for Fisher Price which launched a career and passion for consumer products, particularly toys.

In his free time, Kevin is a passionate sailboat racer, and met his wife while racing in the northeast. Kevin is currently looking forward to his next opportunity and excited to bring his passion for people and consumer centric innovation to his next endeavor.

In our conversation, we discussed the development of the Nerf Ultra and a new material technology that was introduced with the product. We also discussed some of the drawbacks of computer simulation and a product failure they found during physical testing that  they would never have found in a simulation because it was not a part of their model setup. Finally we talk about the importance of boldness and innovation in product development.

Join us as we dive into some of the ins and outs of developing toys for a large market.

In this episode, we meet with the Vice President of Product Development for 360 Electrical. Prior to joining 360 Electrical, our guest worked for several companies developing consumer electronics..

Jonathan Hsieh, whose parents immigrated from China and Taiwan, was born and raised in Los Angeles California. After graduating with a degree in Quantitative Economics from UC Irvine, he had the opportunity to start developing consumer electronics products and hasn’t looked back. In his spare time he loves to read books and listen to podcasts pertaining to mindset.

In our discussion, Jonathan provides an in depth look at what it takes to develop phone cases. From chasing down phone data, to extremely compressed timelines, Jonathan walks us through the fast paced world of developing cases for phones. Outside of the design process, he offers some great wisdom around using rest and recovery to perform your best and some things to be mindful of when selecting vendors.

Join us as we gain a better understanding of what goes into designing and manufacturing phone cases.

In this episode, we meet with the Vice President of New Product Design at PlayPower Inc, the world's largest commercial playground and recreational equipment manufacturer. Prior to joining PlayPower our guest spent 20 years creating award-winning products for consumer product manufacturers including Tomy International, Newell Brands, and Stanley Black & Decker. Outside of work he is an avid outdoorsman enjoying activities like hunting, finishing, running, camping, and hiking.

Joe Palermo leads a team of designers, engineers, and project managers bringing new and innovative play equipment to market under the PlayPower brands, Playworld, Miracle Recreation, and Little Tikes Commercial. A graduate of the University of Cincinnati, Joe now resides in Massachusetts with his wife and eight children.

Joe is passionate about inclusion and is most proud of the teams he has helped build and the people he's been able to empower, allowing them to grow while doing something they love.

In today's episode we take a look at the PlayHill playground equipment by Playworld breaking down the multiple teams of people who combine their ideas and efforts in order to produce the exact layout desired by their clients. Outside of the actual design work Joe also highlights other elements of their product design such as preparing assembly instructions, technical documentation, and meeting safety and compliance standards.

Join us as we peek behind the curtain and take a look at the industrial side of making a fun park for children.

In this episode we meet with a New Product Development Engineer at Pro-Form Custom Packaging who has an extensive history in product design and manufacturing. Our guest has had the opportunity to work in several industries including consumer products, medical, architectural, automotive and even exercise equipment. In his free time he likes to spend time outdoors with his wife of 37 years, 2 adult children and 3 grandchildren. 

Kevin Ackeret grew up in a small town in Southern Indiana where he began his career cutting steel as a tool and die maker in the early 80's and instantly found his passion for design and machining. After a decade working as an engineer and CNC programmer Kevin moved into a role as a design engineer and has almost 35 years of experience working closely with both design and manufacturing teams

Kevin's most recent venture has brought him into the world of product packaging, introducing a whole new realm of challenges to his ever expanding portfolio. In today's episode we begin by discussing the Centurion Rack Repair System, a robust pallet rack product that is modular by design to allow for a plethora of configurations based on the repair requirements. Kevin designed  this system from the bottom up for SpaceGuard Products and provides insight into the design, testing, and manufacturing processes involved in bringing that product to market. 

For the second half of the show we learn more about packaging design. Kevin outlines the design practices used to design packaging, the consideration package designers have for the customer experience, and emerging trends with industrial design to allow for smooth and fast online collaboration between engineers. Kevin provides a very unique perspective and stands as a shining example for anyone looking to get into the industry.

In this episode, we speak with a guest who spent his early career working at Gillette Company as a New Product Commercialization Manager where he played a key role in the development of iconic product lines such as Sensor, Mach 3, Venus, and Fusion. In his spare time he enjoys traveling with his family and spending time with his children and grandchildren. 

Ken Maider is a born and bred Bostonian. He attended Tufts University, earning a Bachelors in Mechanical Engineering with a focus on Engineering Design. After his tenure at Gillette, Ken provided product development consulting for American Safety Razor. He then spent eight years at Keurig, where he contributed to the innovation of K-Cups, soft drinks, and a notable joint venture with Budweiser called Drinkworks.

In our discussion today Ken provides a detailed look at the 4 year long process of taking the Mach 3 razor from initial concept to finished product ready to go to market. Ken's expert knowledge of developing mass consumer products is clear as he walks through the multitude of front end development steps involved in designing a product. From running market tests for proof of concept to distributing thousands of prototype samples to manufacturing and automation engineers in order to prepare for mass production Ken has seen it all.

Join us as we gain a better understanding of the work required when production volume numbers are in the billions and learn a little bit more about the products we see on store shelves everyday.

In this episode we meet with the Head of Innovations and Advanced Concepts at Keurig Dr. Pepper who's path into industrial design was unlike the typical story and has given him the opportunity to work with companies such as Steelcase, Swingline, Disney, and Marvel.

With a diverse background spanning industries from coin-operated video games to household appliances, he has honed his ability to understand and respond to the evolving needs of consumers. In his free time he enjoys flexing his artistic muscles, sketching out architectural designs, and relaxing with his family and friends.

Chris Cunninham was born in Chicago Illinois and his career has been a dynamic exploration of how design can enhance people's lives. From crafting immersive cooking experiences to designing ergonomic office products, Chris's focus has consistently been on creating products that resonate deeply with users. He believes great design is not merely aesthetic; it's a powerful tool for problem-solving and storytelling.

In today's episode we discuss the Fusion Lamination Platform, an innovative lamination product that Chris spearheaded the design of from the ground up. Chris shares his expertise on up-front design and how he was able to use those early lessons learned to plan out packaging and market space while final designs were being completed. He also provides personal anecdotes on the trade-offs within design, the decision making process, and the realities of idea creation.

Join us as we gain a new insight into the industrial design side of product development and better understand the relationships between teams that work in tandem to bring a product to market.

In this episode we speak with the Vice President of Engineering and New Product Development at Hoonigan, a leading automotive aftermarket products company.

Our guest had an extensive career in the automotive product development space, working with a wide range of products from accessories to complete specialty performance vehicles. He's a proud father of 3 adult boys, a pilot and off road racer, and spends his free time in Baja California with the Long Beach Racers team.

Ted Moncure was born and raised in Long Beach California where he still lives today with his wife of 31 years. A graduate from California Polytechnic State University, Ted worked at Toyota for 22 years, including 10 years leading Toyota Racing Development's (TRD) performance accessory team.

After leaving Toyota in 2015 Ted joined Transamerican Auto Parts where he spearheaded the engineering of trucks and off-road products under the 4 Wheel Parts brand. When 4 Wheel Parts was acquired by Hoonigans in 2021, Ted took on the role of VP of Engineering, overseeing a wide range of products from wheels to suspension systems, accessories, and lighting.

In our conversation, we discuss the intricacies of developing aftermarket suspension systems for trucks and SUVs. Ted shares his expertise on the process of measuring vehicles, evaluating safety systems, and fine-tuning suspensions to maintain stability and performance. We also discuss the challenges of staying compatible with vehicle software and how aftermarket changes can impact vehicle performance.

Ted emphasizes the importance of testing and validation in product development, the need for rapid development cycles, and the role of 3D printing in modern engineering. Ted's wealth of experience makes this a fascinating discussion for anyone interested in motorsports engineering.

In this episode, we speak with a Senior Engineering Executive whose efforts within the automotive industry helped to develop an internal radio system that provided the building blocks for products we see today like OnStar or the Amazon Alexa.

Our guest's extensive career has seen him contribute to industry sectors including oil and gas, technology, industrial goods, robotics, and AI development. In his down time he enjoys passing his knowledge and experience to his children, teaching his daughter new technologies, how to code, 3D printing and anything related to AI development.

Art Casasa was born in Veracruz, Mexico, where he lived until he finished his studies in Mechanical and Industrial Engineering. At the age of 24 his quest for knowledge and expertise brought him to the United States, where he completed his graduate studies, earning an MS in Manufacturing Engineering, an MBA, and a Masters of Finance. He also obtained a Postgraduate Certificate in Artificial Intelligence and Machine Learning from the University of Texas at Austin and is currently pursuing a Master's in Artificial Intelligence at Penn State University. Art, his wife Marcela, and their two children now reside in the greater Houston area.

After gaining valuable Operations experience within the automotive industry, Art shifted his focus to new product introductions, working with Tier One suppliers on product development.

In this episode we discuss Art's groundbreaking work in the automotive industry, and the process that brought his radio system to life. We explore the challenges and achievements of developing this system, we discuss a different perspective of prototyping for a system instead of a product, and the importance of testing for reliability and quality. Finally we speak on rising trends within the industry including designing for sustainability, AI's impact on generative design, as well as the past, present and future of 3D printing.

In this episode we meet with former Senior Director of Engineering at Fortune Brands Innovations, a company who's portfolio of brands includes Aqualisa, Emtek, Therma-Tru, Fiberon, Master Lock, and SentrySafe.

Our guest has over three decades of experience in developing new products, generating value, and overseeing multi-million-dollar facilities and equipment upgrades across various industries. Outside of his professional life he enjoys fishing, particularly traveling to coastal destinations and targeting new species to catch.

Scott Losik was born and raised just outside Detroit, Michigan. He obtained his degree in mechanical engineering from Michigan State University and kicked off his career at Ford Motor Company and eventually earned a Master's degree in Automotive Engineering from the University of Michigan.

At Ford's engine lab in Dearborn, Scott specialized in engine testing and played a pivotal role in establishing new test facilities and capabilities, handling everything from testing methodologies to strategic planning and project management. Scott's expertise eventually led him to Fortune Brands, where he initially focused on faucets before expanding into building products like doors and decking.

In our discussion we learn about the product development project that Scott spearheaded called the Hybrid Valve. This innovative product platform simplified over 50 bath faucet configurations into just five valve assemblies that can be repeated across multiple products. We explore the challenges of developing the product platform, the importance of collaboration with marketing and design teams to isolate key requirements, and the value of understanding customer needs.

Scott shares insights into the benefits of platforming and the impact it has on a business, and we discuss the potential role of AI in product development for concept design and marketing insight. Scott provides a unique perspective on product development speaking from a project leadership perspective and analyzing how small decisions upfront have large impacts with a team down the line.

In this episode we speak with the Vice President of Product Development at Artica Collective, a company responsible for product brands like Slumberpod, Colugo, EverSprout, and Doctor's Choice.

Our guest brings a wealth of knowledge in the world of product design and development with over 16 years of experience in various industries, including consumer goods, fishing and outdoors, furniture, packaging, office supplies, medical supplies, home storage and organization, juvenile products, and home decor. Outside of his professional life he enjoys fixing things, making things better, and has recently become addicted to completing escape rooms with a group of friends.

Gabe Prero hails from Chicago, where he still resides with his wife of 18 years, their four children, and a yellow lab. He earned his BFA in Industrial Design from the University of Illinois Chicago. Known for his technical design skills, problem solving abilities, and expertise in design for manufacturing (DFM), Gabe has successfully brought dozens of products to market and holds over 20 patents.

In the episode we discuss the development of a modular closet organization system called Closets by Liberty from Liberty Hardware. We explore the challenges faced in creating this easy-to-install system, the importance of addressing customer concerns, and the critical role of research and prototyping.

Gabe shares insights into the involvement of a dedicated team, the trends in product development, and his advice for those aspiring to make a significant impact in the industry. In a world where bringing a product to market is a massive and complicated endeavor Gabe does a wonderful job of breaking the process down into a collection of entertaining stories.

In this episode we meet with the Vice President of Product Development at MillerKnoll, a company that specializes in workplace furniture. Our guest is an avid game player spending his free time honing his skills in activities like volleyball, tennis, cornhole and darts. He also enjoys spending time with his wife and two daughters.

Larry Kallio was born and raised in Lansing, Michigan. He went on to study Math and Statistics at Grand Valley State University, initially aspiring to be a high school math teacher and swimming coach. After college, Larry's career took a different turn, landing a part-time job at Steelcase, which soon evolved into a full-time role in office furniture custom development.

In 1999, after 5 years at Steelcase, Larry joined Herman Miller, now MillerKnoll, as a development engineer. Over the past 24 years he has made significant contributions to the company, leading product development and customization efforts.

Today we'll be diving into some of Larry's most notable work, specifically the development of the Renewed Height Adjustable Table. We'll explore the development process, from the initial timeline and team involvement to the key milestones and the prototyping process. Larry shares insights into the use of diecast parts for testing and the challenges faced with making world class furniture. Additionally he'll offer valuable advice for those looking to make a significant impact in the product development industry.

Join us as we learn from Larry's wealth of experience and gain a deeper understanding of the art and science of product development.

In this episode we speak with the Engineering Manager at FHE and discuss the Riglock 2.0 a product used in the oilfield industry to improve safety and boost productivity. Our guest is an avid inventor spending his winters in his garage 3D printing functional products and printing parts to make and upgrade 3D printers. Summers on the other hand are enjoyed at the lake with his family.

Matthew Kibler began his engineering career in 1996 working in a laboratory where he developed multi-axis titration dispensing robots. These early innovations in laboratory automation may have inspired the 3D printing technology we see today.

In 2002 Mathew transitioned to the product packaging industry, joining a company where he spent 15 years developing high-speed folder gluers, packers, and flame sealers. His journey from draftsman to CAD Manager, to Lead Design Engineer underscores his expertise and dedication to engineering excellence. In 2017, Matthew brought his wealth of experience to FHE, where he began as the sole Design Engineer. Through his leadership and vision, he built and expanded the Engineering team, becoming the Engineering Manager in 2023.

Today, we'll dive into the design process of the Riglock 2.0, exploring its features and the challenges faced in development. Matthew shares insights into the product development timeline, the impact of technology on this process, and the importance of safety and validation in product design. We'll also discuss trends in product development, strategies for improving development timelines, the importance of having a strong understanding of the tools you use and where that can take you.

In this episode we speak with the Director of Engineering at Trim-Lok Inc. a company that specializes in the manufacturing of rubber and plastic extrusion products. Trim-Lok's high-quality sealing and trimming solutions are used across various industries including automotive, marine, industrial, and recreational vehicles.

Our guest today has amassed a wealth of experience working for various large and small corporations, including Lockheed, pfizer, mattel Toys, and Rainbird. He has earned a total of 12 patents and founded his own development company, 2N2 which specializes in industrial design, product design, and tooling design, creating everything from housewares to computer electronics. Beyond his professional achievements he is a dedicated family man. He's been happily married for 21 years and is a proud father to his 19 year old triplet boys. In his free time he enjoys woodworking, playing golf, and working out.

Ken Siegel has been a driving force at Trim-Lok for the past 18 years but Ken has a lifetime of design and development experience holding down every role from inventor to executive. Today we begin by discussing a folding hanger and a specialized plastic handle, two products Ken personally developed and brought to market.

Ken recounts his diverse experiences working with a cat litter company as well as his time at Procter & Gamble where his strategic influence had a direct impact on the trajectory of their Tide products. He also shares an example of a custom extrusion project and how his team successfully overcame the obstacles they faced. Throughout every story or example Ken provides valuable insight into the importance of adaptability and resilience in product development, emphasizing how failure can serve as a powerful growth mechanism. Ken hopes to encourage aspiring product developers to stay persistent and never give up.

IIn today's episode we speak with a Senior New Product Development Engineer from Ambu (Am-boo), a Denmark based medical device company specializing in devices for use in anesthetic procedures.

Born in Southern Indiana, he attended the University of Evansville where he excelled both academically and athletically, running Division 1 Cross Country while earning a BS in Mechanical engineering with a minor in Math.

Today he resides in the Indianapolis area with his wife and 2 children, spending his free time involved with the local running community and working as an assistant coach for a nearby high school.

Sam Mires has been with Ambu for 4 years working at the forefront of numerous successful product launches and has a keen insight into the challenges of developing medical devices in a highly regulated industry.

In today's episode we explore the development of Ambu's Viral Bacterial Filter, a device designed to enhance patient safety during respiratory use. We discuss details of the development process and look into the technical aspects of the project such as injection mold tooling, process validation, and the importance of cross-functional teamwork.

Furthermore Sam provides insight into the importance of understanding customer needs, the push for sustainable product development, and the trends shaping the future of the medical device industry. Join us as we explore Sam's journey within product development and the lessons he's learned along the way .

In today's episode we speak with the Founder of WJ Titan, an ISO17025 accredited inspection lab focused strictly on the inspection needs within manufacturing. He was born and raised in Fort Wayne, Indiana and graduated from the then called, IPFW in Fort Wayne with a Marketing degree. When he's not taking micron level measurements he enjoys golfing and spending time with his wife Emily and their 3 children.

Jim Rorick began his career in the calibration and inspection industry with little prior knowledge but quickly realized it was the perfect fit for his skills and passion. After gaining professional experience and navigating a couple of acquisitions, he and a partner decided to take the leap and started WJ Titan has become a trusted name, helping manufacturers across various industries ensure their parts and specialty gauges are correctly made.

In today's discussion we discuss the multitude of tools in Jim's inspection lab used to take highly accurate and detailed measurements. We talk about communicating with clients, understanding their requirements and finding a healthy balance between working fast and performing good, precise work. We learn how each part comes with its own unique challenges and get a strong understanding of how a part moves through the quality assurance process. Join us as we develop a new understanding of an often overlooked process and gain some sympathy for the teams of people working hard to help us hit our deadlines

In this episode, we dive into the world of optical design learning about the design challenges and complexities of optical systems as well as some of the instruments used in photo labs.

Jacob Wimmer is a seasoned Optical Engineer with a lifelong affinity for lighting. Jacob's journey into the world of optical design began at a young age, spending his summers immersed in his father's optical design business, Charlevoix Design.

Little did he know then, those early experiences would shape the trajectory of his career. After studying architecture at the University of Michigan, Jason drew upon his lighting background to land a position with an architectural lighting design firm in New York City. But the call of home beckoned, and Jacob returned to northern Michigan, where he now co-manages Charlevoix Design alongside his father, Chris.

Beyond his professional pursuits, Jacob finds solace in the great outdoors, where he shares adventures with his wife and two young daughters. An avid hiker, he's tackled over half of the Appalachian Trail. He also enjoys bow hunting for white tail deer in Michigan and for elk when he can make it out to the western states.

Charlevoix Design thrives on diversity, servicing clients across various industries, from illuminated logos to automotive headlights. In our conversation today we uncover how Jacob collaborates with clients to overcome challenges in material definition and system integration and hear about Jacob's experience revolutionizing snow blower lighting. Join us as we dive into the illuminating world of optical design.

In this episode we talk with a yacht designer about the exciting and challenging world of yacht design.

Matt Welton grew up in Mid-Michigan where his summers were spent immersed in boating, skiing, and swimming Those formative experiences instilled a deep love for the water and a fascination with yachting.

Following his passion, Matthew attended The University of New Orleans to pursue degrees in Naval Architecture and Marine Engineering. When he's not designing yachts, Matthew can be found spending the majority of his free time either on or around water.

At the beginning of 2024, Matthew took a bold step away from the corporate world to establish MW Yacht Design, a yacht design consultancy driven by his passion for innovation and excellence in yacht development.

In our conversation Matthew shares insights into one of his favorite projects, the Ocean 1 470, discussing its unique mission and the advanced technology onboard. We also explore the evolving landscape of yacht design, touching on trends like automation and electrification, and the impact these advancements have on the industry.

Matthew offers a holistic perspective on yacht design, emphasizing the importance of both creativity and technical expertise in shaping the future of ocean luxury. Join us as we set sail into the fascinating world of yacht design with Matthew Welton

In this episode, we talk with an innovation and product development expert with over three decades of experience. He has been a guiding force for companies spanning the spectrum from startups to Fortune 500 giants, helping them through the journey from product concept to commercialization with unparalleled expertise. When he's not hard at work Tom enjoys spending his free time with his wife and family.

Dr. Tom Foust's career has seen him collaborate with an impressive array of clients, including industry titans like Eli Lilly, Takeda Pharmaceutical, Frito-Lay, and Delta Faucet, and many others. Notably, he's the driving force behind the groundbreaking aqueous ozone technology, swiftly bringing it to market through his company, 30e Scientific which was honored with the Edison gold Award in 2022 for its innovative product, "Iggy."

Beyond his corporate endeavors, Tom is a renowned scholar and educator. He's an Associate Faculty Member at IUPUI in Indianapolis, and has lectured at institutions such as Oxford University and the University of Birmingham, where he holds an honorary professorship. He's also an author of two books alongside numerous publications and keynote speaking engagements worldwide.

Today we have the privilege of sitting down with Dr. Foust to explore the intricacies of front-end product development and the keys to fostering innovation in today's fast-paced world. In our conversation we'll take a look at Tom's latest product the "fur hero" and the pivot it made to get where it is today. We'll also discuss Tom's approach to identifying extreme users, the symbiotic relationship between designers and engineers, and the impact of strategic advisory roles in executive decision-making.

In this episode we talk to a long-time colleague of mine who loves playing golf, practicing his guitar and even once played on stage with the 90's band Oleander.

Todd Reese is the President of Realize Inc. a prototype and 3D printing service provider.

In our conversation we discuss a variety of topics within the realm of additive manufacturing and prototyping.

From the intriguing origins of Realize Inc. to the meticulous processes involved in 3D printing. Todd shares valuable insights into the company's capabilities and specialized services.

We also dive into the importance of client education, exceeding client expectations, the technical aspects of material selection and which CAD files are most often used.

Strap in and get ready to learn about the evolution of consumer-level printers, the impact 3D printing has on a product's time to market, and the significance of preserving design details within the rapid prototyping industry.

In this episode we talk to a polymer engineer who's upbringing in Brandenburg, Kentucky infused him with a spirit for exploration and a love for music. He has a 5 octave singing range and grew up honing his skills playing trombone in various bands.

Todd Cook is an R&D Engineer for Cook Polymer Technologies. Todd works in partnership with Cook medical group to develop medical components used in minimally invasive surgical equipment.

A scholarship from the National Science Foundation to study math modeling set him on a path toward engineering, but it was during his co-op experiences that Todd first discovered his passion for polymers. Todd's expertise in polymer engineering has led him to develop products for industry giants like GE, Electrolux, and Remington Arms.

Additionally Todd, alongside his friend Paul Nash, co-founded polymer eClub, an online platform dedicated to advancing polymer skill development with a focus on real-world application.

In today's show we discuss the Remington Supercell Recoil Pad and learn how Todd was able to recognize a winning idea that meets all the requirements of a successful product from material advantages to market need.

Todd's advice on navigating the twists and turns of product development is a goldmine for aspiring designers. From idea inception to final product, he's been through it all and has plenty of stories to share.

Todd's enthusiasm for innovation is obvious especially when he talks about the potential of AI in creating complex and effective product models. He's all about pushing boundaries and exploring new possibilities. But it's not all smooth sailing. Todd knows firsthand the importance of persistence and grit in the face of challenges. He's here to remind us that every setback is just another opportunity to learn and grow.