Douglas Schaller is a full-stack industrial designer crafting impactful products at the intersection of biotech, sports, and consumer tech. From lab bench to bike accessory to smart device, he brings a maker’s mindset and a systems approach—blending precision with performance, and vision with viability. Whether engineering for the human body or pushing the limits of user experience, his work rides the line between innovation and intuition.
Comprehensive Industrial Designer
Sketches and Ideation
Design often begins with putting thoughts on paper—or screen. For Douglas, it typically starts with pen to paper and a lot of questions. These early sketches, like the examples shown, are where exploration begins and ideas start to take shape.
Computer Aided Design(CAD)
Whether developing early-stage concepts or engineering complex parts for manufacturing, Douglas approaches CAD with a rare combination of creativity and precision. His fluency in digital modeling allows him to seamlessly transition from ideation to production-ready design, ensuring that every detail is thoughtfully resolved. With a strong foundation in DFM (Design for Manufacturing) principles, he not only visualizes compelling products, but builds them to be real, reliable, and manufacturable.
Mock-ups and 3d Printing
Douglas thrives on hands-on exploration, and building mock-ups is one of his favorite parts of the design process. Whether it’s a quick cardboard-and-duct-tape model or a precisely milled prototype from a 3D printer or desktop CNC, his goal is the same: to test, validate, and refine ideas. These physical models serve as proof of concept—helping uncover insights about form, function, and feasibility early in the process.
Renderings
Unsure how a product will look in a specific material or finish? That’s where photo-realistic rendering comes in. These high-fidelity visuals allow us to evaluate form, color, and texture—long before anything is manufactured. And yes, the image here might look real... but it’s not
Design For Manufacturing
Preparing to bring a product to market? Douglas has the experience to guide it across the finish line. With a deep understanding of design for manufacturing, he specializes in translating concepts into production-ready solutions—across plastics molding, sheet metal, machining, die casting, and extrusion. His hands-on knowledge ensures your product is not only well-designed, but manufacturable at scale.