product design
end-to-end
Vapor Polish Experiment: SohlbeDesign's CEO, Christopher Sohlberg
"The details are not the details: they make the design" - Charles eames
SohlbeDesign:
Over a Decade of Design Excellence
Design
SohlbeDesign represents 12+ years of end-to-end product design engineering across consumer-adjacent electro-mechanical hardware, regulated Medical Devices, Prototype Job Shops, Freelance Development, and Aerospace Programs. The work spans the full product lifecycle translating ambiguous needs into measurable requirements, selecting architectures and materials, and driving iterative CAD and rapid prototyping to converge on solutions that are functionally robust, manufacturable, and ready to ship. From concept inception, SohlbeDesign emphasizes constraint-driven design: Defining interfaces, envelopes, load paths, assembly sequences, and critical-to-function dimensions early, then using tolerance analysis and GD&T to control variation and ensure repeatable fit, performance, and cosmetic outcomes. Prototypes are treated as learning vehicles, built quickly, instrumented intelligently, and used to refine designs through characterization testing, failure analysis, and DOE-informed iteration. Where needed, custom test fixtures and measurement systems are developed to generate defensible data that accelerates design decisions and de-risks design locks. As programs mature, focus shifts to production readiness: DFM/DFA optimization for high-volume processes (injection molding, machining, stamping, and secondary operations), material and joint strategy (plastics, metals, adhesives, glass and surface finishes), and supplier execution that closes the loop from RFQ and tooling kickoff through pilot builds, DV/PV-style validation runs, and manufacturing ramp. SohlbeDesign has repeatedly partnered with overseas vendors to drive tooling feedback, manage change control, and ensure incoming quality translates into stable assembly yield, reliable test performance, and on-time shipment. The result is a portfolio built around ownership, delivering hardware systems from first prototype to production release with a practical, data-driven approach that balances performance, cost, schedule, and customer experience.
SohlbeDesign represents 12+ years of end-to-end product design engineering across consumer-adjacent electro-mechanical hardware, regulated Medical Devices, Prototype Job Shops, Freelance Development, and Aerospace Programs. The work spans the full product lifecycle translating ambiguous needs into measurable requirements, selecting architectures and materials, and driving iterative CAD and rapid prototyping to converge on solutions that are functionally robust, manufacturable, and ready to ship. From concept inception, SohlbeDesign emphasizes constraint-driven design: Defining interfaces, envelopes, load paths, assembly sequences, and critical-to-function dimensions early, then using tolerance analysis and GD&T to control variation and ensure repeatable fit, performance, and cosmetic outcomes. Prototypes are treated as learning vehicles, built quickly, instrumented intelligently, and used to refine designs through characterization testing, failure analysis, and DOE-informed iteration. Where needed, custom test fixtures and measurement systems are developed to generate defensible data that accelerates design decisions and de-risks design locks. As programs mature, focus shifts to production readiness: DFM/DFA optimization for high-volume processes (injection molding, machining, stamping, and secondary operations), material and joint strategy (plastics, metals, adhesives, glass and surface finishes), and supplier execution that closes the loop from RFQ and tooling kickoff through pilot builds, DV/PV-style validation runs, and manufacturing ramp. SohlbeDesign has repeatedly partnered with overseas vendors to drive tooling feedback, manage change control, and ensure incoming quality translates into stable assembly yield, reliable test performance, and on-time shipment. The result is a portfolio built around ownership, delivering hardware systems from first prototype to production release with a practical, data-driven approach that balances performance, cost, schedule, and customer experience.
Prototype
Validate
Produce
ship
Portfolio projects
Some projects were completed under NDA or within regulated environments. To respect confidentiality and IP, visuals are limited and certain details are generalized or redacted. I’m happy to discuss my specific ownership, tradeoffs, validation methods, and outcomes in an interview.
Injection-Molded Light Pipe + Diffuser Optimization (DOE)
Led a DOE-driven redesign of a disposable biomedical light-delivery consumable, replacing a high-cost fiber-optic assembly with a PC injection-molded light pipe and snap-fit diffuser interface. Owned geometry optimization across optical performance and mechanical robustness; iterating snap retention features, defining insertion/retention specifications, and partnering with an overseas supplier (Korea) on prototype tooling with swappable inserts to rapidly test geometry/material variants. Using a characterization-based feedback loop to lock CTQs, the final design doubled irradiance output, reduced COGS by ~87%, and cut therapy time by ~50%, enabling higher throughput over the laser’s service life and supporting on-time readiness for a Phase III FDA clinical trial.
Designed and delivered an adjustable 0.5–3.0W laser subsystem in close partnership with an EE, owning the mechanical/product integration across architecture, packaging, and validation. The system integrated three PCBAs, controlled flex-cable routing, a front panel with soft-touch buttons, and a thermally managed enclosure. I developed iterative prototype builds and a data-driven thermal solution using 3D-printed cooling ducts informed by analysis and then refined with measured temperature/airflow data, feeding results back into final geometry and design lock. The outcome was a production-ready electro-mechanical assembly with validated performance, robust routing/assembly features, and a clear path to repeatable manufacturing.
Designed and delivered an adjustable 0.5–3.0W laser subsystem in close partnership with an EE, owning the mechanical/product integration across architecture, packaging, and validation. The system integrated three PCBAs, controlled flex-cable routing, a front panel with soft-touch buttons, and a thermally managed enclosure. I developed iterative prototype builds and a data-driven thermal solution using 3D-printed cooling ducts informed by analysis and then refined with measured temperature/airflow data, feeding results back into final geometry and design lock. The outcome was a production-ready electro-mechanical assembly with validated performance, robust routing/assembly features, and a clear path to repeatable manufacturing.
Compact adjustable
laser Design
Auto-Iris Airflow Restrictor Automation (FTY + Cycle Time)
Designed and deployed an automated “auto-iris” airflow restrictor to eliminate operator-dependent setup steps in end-of-line test for a medical device. Replaced manual swapping of restrictors (adult vs toddler simulation) with a sealed motorized iris mechanism that tunes opening area to hit required back-pressure targets, removing a common human-error failure mode. Defined the calibration and control approach (position mapping to pressure/flow spec), delivered a robust prototype-to-production fixture upgrade, and integrated it into the test line. Result: eliminated restrictor-related escapes and helped sustain first-time yield in the high-80% range, while reducing retest-driven cycle time.
Flic Redesign
Redesigned the mechanical enclosure for Flic button internals to achieve a slim, premium “coin-like” form factor while preserving full functionality. Reverse-engineered the internal stack and developed a 3-part self-locking housing with a dedicated assembly/disassembly tool, using tolerance-driven GD&T to control critical fits at very small scales. Leveraged compliant preload from the battery insulation layer to stabilize the latch condition, integrated a clean LED light path, and partnered with an Asia supplier to deliver three functional prototype iterations. Final concept achieved a ~8 mm profile, magnetic attachment, and production-feasible assembly intent suitable for client handoff.
bio-lab
test automation
Designed and delivered a timing-critical bio-lab test automation system to enable statistically defensible DOE data for a 665nm optical therapy program under Phase III clinical trial deadlines. Owned the end-to-end fixture architecture: precision fixturing of custom autoclavable test wells/adapters (including crystal-clear urethane casting), tolerance-controlled light-pipe/diffuser positioning, and an error-proofed operator workflow compatible with dark hood operation and IPA/autoclave cleaning. Integrated automation using a programmable timer relay, pneumatics with tuned flow control (spill-free insertion/removal), foot-switch actuation, magnetic sensing for laser enable/disable, safety interlocks, and manual override modes. Qualified the measurement approach with Gage R&R <20% and 95% confidence, released documentation through an FDA/QMS process, and delivered a working system in ~3 months, providing the data runway needed for DOE analysis and trial submission; while also feeding learnings back into light-pipe geometry and irradiance profile optimization.
Electro-Pnuematic Offloading System
Retrofitted an automated break-over assembly tool into an electro-pneumatic offloading system to prevent satellite panel deflection that was blocking critical feature alignment. Designed and integrated 4 pneumatic cylinders across a fixed tool and a mobile roll-in station, including the full pneumatic architecture (valves, regulators, gauges, safety/relief strategy) and a custom quick-connect plug/socket interface for repeatable operator use. Owned the program end-to-end—force/pressure sizing calculations, prototyping, PDR/CDR, vendor sourcing, weldment detailing, and release of a complete drawing + build package—enabling consistent alignment during assembly operations.
Compression Molding Process + Tooling Development
(Medical-Grade Silicone)
Owned end-to-end development of multiple compression-molded silicone components, spanning part design, tooling design, and production process definition for repeatable output. Designed five molded parts and the corresponding mold tooling, programmed equipment and built fixtures to manufacture the molds, sourced medical-grade silicone, and established a closed-loop shrink compensation method by molding test coupons, measuring shrink rate per material/lot, and applying offsets into mold geometry prior to tool lock. Developed and validated the full process window—platen press temperature, pressure, dwell time, release strategy, and venting—then troubleshot defects (fill/air entrapment/flash) through iterative tool and process refinements. Delivered a manufacturable, documented molding process capable of consistent quality and scalable production.
Adjustable kick Stand and lowering link
Developed an adjustable ride-height and support solution for a KTM690 by reverse-engineering the stock components and iterating rapidly from physical hardware to production-feasible geometry. Removed and measured the OEM kickstand and linkage, captured 3D scans, stitched the scan model, and rebuilt parametric CAD in SolidWorks to design dual-orientation lowering links enabling ride-height adjustment (+1.o / –1.5 in) . Designed a matching adjustable kickstand with a sliding foot and clamp-lock mechanism (slotted compliance feature + dual fasteners) to maintain stability across configurations. Delivered multiple 3D-printed prototype iterations, validated fit/function on-bike, and handed off a finalized design package for client sourcing and production.
More Examples and Details Upon Request
Fun Home Design Projects
Creative Outlets when not at work!
Electro-Mechanical Projects
Car Build Projects
Music Projects
Contact Info
SohlbeDesign Portfolio
360-461-0969
Explore innovative mechanical design solutions.
6618 133rd PL SE, Snohomish, WA 98296
6618 133rd PL SE, Snohomish, WA 98296