Physical computing device
I led physical design for a new interactive computing device that would interface with an EdTech company’s paper circuit ecosystem. The goal was to create a product that was intuitive for children, robust enough for classrooms, and affordable for teachers—while solving reliability issues of previous products.
My work spanned concept development, CAD, 3D printing, iterative prototyping, and user testing. In later phases, I collaborated with electrical and production engineers to refine the design for manufacturability, cost, and a frictionless user experience. Across the project, I applied hands-on prototyping, creative problem solving, and a human-centered approach to make physical-digital interactions more accessible and engaging in the classroom. My work was central to the project securing a $1M commercialization grant.
Research
Research was two-pronged, focusing simultaneously on user experience and on technical feasibility. From a technical perspective, I researched a variety of clipping and conductive mechanisms, purchasing a variety of off-the-shelf components to try out. From a user perspective, we surveyed and conducted focus groups with a number of educators and makers.
Ideation
I developed concept sketches to explore mechanisms and form factors, with a focus on usability, reliability, child ergonomics, classroom safety, and a friendly, approachable aesthetic.
Prototyping
The first round of prototyping focused on defining a mechanism that could deliver reliable electrical connections—a key weakness of the original product. I began with quick “paper prototypes” made from cardboard and off-the-shelf parts to test clipping actions and user interaction.
From there, I moved into CAD and 3D printed iterations. Through this process, I developed a compliant mechanism that adapted to uneven paper surfaces like cardboard, ensuring consistent electrical contact across all pins. User testing with educators and students showed significant improvements in reliability compared to the earlier products, and my work contributed to securing a $1M grant for commercialization.
Testing & Iterating
We shipped educators working prototypes to user and test in their classrooms. Using the feedback from these play tests, surveys, and focus groups, I began to revise and iterate upon the concept.
I collaborated closely with an electrical engineer and a production engineer to refine the design for manufacturability, cost, and improved user experience. This included exploring form factors suitable for injection molding, integrating compliant conductive components into PCBs, and investigating scalable assembly methods. We paired this with user research to refine usability and ensure a frictionless interactive experience for students and educators in the classroom.
The project is currently on hiatus due to funding changes, but the work demonstrated a clear pathway to a scalable, classroom-ready product that merged mechanical design, user research, and creative problem solving into a tangible, engaging STEM tool.