Designing for Comfort & Customization

Rethinking Wireless On-Ear Headphones
Over the years, I’ve designed all kinds of products, but one thing remains true—true innovation comes from solving real user pain points.

We’re excited to be collaborating with Beautiful Audio, known for their NZ Merino wool earpads, to pair their premium materials with a custom-designed lightweight headband and earcup system.

The goal? A listening experience that blends mechanical precision with natural comfort.

I'll be prototyping this design myself, using off-the-shelf component modules and refining the mechanics to ensure smooth, simultaneous earcup adjustments.

Looking forward to the challenge—because small mechanical innovations can make a big impact on user experience.

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Design for Manufacture…CNC Prototyping vs. Injection Molding

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Optimizing Designs with FEA