Personal Fitness Equipment
Summary
Our client developed a leg compression recovery device but faced challenges with its bulky design, high manufacturing costs, and lack of an integrated display. We streamlined the design by creating feasibility prototypes, optimizing manufacturability with modular rugged components, and enhancing the user experience with an improved boot connection system. The redesigned product launched successfully, leading to a follow-up project three years later to create a more compact, backward-compatible version with additional accessories.
Problem
Our client developed an innovative device designed to aid post-exercise recovery by using targeted leg compression across different zones. However, the initial design had significant limitations—the main control unit was housed in a bulky Samsonite Vanity case, and each unit required a long and complex manufacturing process. Recognizing the potential of his product, the company owner sought a way to significantly reduce both the size and production costs while maintaining functionality. Additionally, he wanted to integrate a display screen into the device, with a cost-effective variant utilizing a custom segmented LCD screen.
Solution
To address these challenges, we explored multiple feasibility concepts and rapidly prototyped them using rigid foam models. This approach allowed us to quickly evaluate different size and shape options, ensuring alignment with the client's expectations. During this phase, it became clear that the design of the connection between the compression boots and the main unit would be critical to delivering an intuitive and seamless user experience.
Once a viable concept for the form factor was established, we refined the design further, focusing on optimizing manufacturability. We strategically divided the unit into modular, easy-to-mold components while ensuring durability through a ruggedized construction. Internal components were securely mounted within a chassis featuring integrated shock-absorbing elements, enhancing both longevity and reliability.
Upon its launch, backed by a large-scale marketing campaign, the redesigned product was met with immediate success. Its strong market reception reinforced the value of our design approach. Three years later, we were entrusted with developing an even more compact iteration, maintaining backward compatibility with the original version while expanding the product line to include a new range of accessories.
Video
This new version was:
- 27 percent smaller while maintaining all the same power and even more functionality than previous models
- Equipped with enhanced robustness and durability including chemically enhanced glass and ergonomic upgrades
- More attainable, with a debut price point at $200 less than the 2018 PULSE Series
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