Outdoor Product Line Design

This project began as a University of Auckland research collaboration, where I led the ground-up design and development of an ultralight sub-1 kg composite tent prototype for Composite Developments. The work focused on reducing weight without compromising structural integrity, requiring extensive concept development, iterative design, technical drawing production, and composite engineering. I was responsible for translating performance requirements into a manufacturable design, supported by prototyping, testing, and refinement to achieve a commercially viable solution.

Following the success of the initial prototype, Composite Developments contracted me to further develop a two-person ultralight tent and to design a multi-discipline adaptable hiking pole system. This included direct communication with overseas manufacturers, refining designs based on prototyping feedback, and supporting the transition from concept to production. A key outcome of the project was the introduction of carbon fibre pole systems into Orson Outdoor tents, a first for the product line, improving both weight efficiency and stiffness.

Across both developments, I contributed to full product lifecycle delivery — from initial concept and structural design through to manufacturing coordination and commercialisation — demonstrating applied expertise in lightweight composite design, product development, and real-world engineering implementation.