Eric Boles

Prototype Development

Physical prototypes are an essential part of my design process. While CAD models communicate form and engineering intent, hands-on prototypes reveal how products feel, function, assemble, and interact with users. Throughout my career, I have built appearance models, ergonomic studies, and functional prototypes to evaluate design decisions before production.

Not every prototype serves the same purpose. Some are built to evaluate ergonomics, others to validate assembly, appearance, user interaction, or manufacturability. Selecting the right type of prototype at the right stage of development is an important part of reducing risk before production.

 

Rethinking Kitchen Knife Ergonomics - Ergonomic Concept Prototype

While working as a cook during college, I noticed that professional chefs rarely held kitchen knives the way their handles were designed to be used. Rather than wrapping the entire hand around the handle, most chefs gripped the blade itself for greater control and precision. Existing knife designs didn't support this technique, creating an opportunity to rethink the relationship between the blade and the handle.

I developed a series of ergonomic concepts that blended the handle into the blade, allowing the user's grip to transition naturally while improving comfort, control, and safety.

After the concepts were made public, similar ergonomic handle transitions began appearing in products from numerous knife manufacturers, reflecting a broader shift toward grips that better supported professional cutting techniques.

The handles were carved from a resin block on a CNC router. The blades were hand-shaped from nylon and painted to resemble metal.

 

Wearable Renal Monitor Prototype - Functional Wearability Prototype

This functional prototype was developed to evaluate the practicality of a wearable renal monitor before committing to production tooling. The prototype allowed the team to assess patient comfort, ease of donning and removal, interface accessibility, and overall wearability while identifying opportunities for refinement early in the development process.

To accurately simulate the production concept, I fabricated the inner sleeve from thermoformed sheet plastic, assembled the enclosure using mechanical fasteners and PEM inserts, and incorporated flexible exterior covers manufactured by an outside supplier. The interior was fitted with foam padding and an adjustable hook-and-loop closure to replicate the intended patient experience.

 

IV Heater and Bubble Detector - Full-Scale Appearance Prototype

This full-scale appearance prototype was developed to evaluate the chosen enclosure design before production. Fabricated from urethane foam with production-style hardware, the model accurately represented the product's size, proportions, assembly, and user interaction. A plaster surface coating and painted finish simulated injection-molded plastic, providing a realistic representation for client review and trade show demonstrations while supporting final design decisions prior to manufacturing.