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CAGLA KUCUKERGORSenior Industrial Designer
Consumer Products
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Case Study 03

CONSUMER
PRODUCTS

Blending aesthetics and functionality for high-volume consumer electronics.

Role
Product Designer
Focus
UX & Injection Molding
Tools
SolidWorks, Rhino, Keyshot
Outcome
Mass Production

Design Specs

Material StrategyPC/ABS blends for impact resistance and high-quality surface finish.
InterfaceCapacitive touch integration with hidden-until-lit LED displays.

DFM Constraints

  • Draft Angles: Min 1.5° for textured surfaces.
  • Wall Thickness: Uniform 2.0mm to prevent sink marks.
  • Assembly: Snap-fits designed for automated assembly.
The Challenge

Seamless Smart Home Integration

The goal was to design a smart thermostat that felt less like a gadget and more like a premium architectural element. The device needed to be intuitive to use while housing complex sensor arrays and wireless connectivity modules.

Thermostat Render 1
Figure 01
Front Interface Design
Thermostat Render 2
Figure 02
Side Profile & CMF
The Solution

Minimalist Complexity

I utilized Rhino for surface modeling to create a continuous, soft-touch form that invites interaction. The internal architecture was rigorously engineered in SolidWorks to ensure perfect alignment of the PCB, sensors, and display stack.

CMF Strategy

Selected a bead-blasted aluminum frame with a chemically etched glass front to minimize fingerprints and glare.

Packaging Design

Designed the unboxing experience to be as premium as the product itself, using molded pulp trays for sustainability.

Project Outcomes

  • 1
    Design Award WinnerRecognized for excellence in consumer electronics design.
  • 2
    High Yield RateOptimized tooling design resulted in a 98% yield rate during mass production.
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