Brandon K.

PCB Design & Packaging Development Specialist

Cadco Design Studio • Freelance

Jun 2025 - Jul 2025 • 1 mo

BrightCore Innovations needed a functional PCB design and retail-ready packaging for a new smart home sensor product. Problem → The client had a basic circuit idea but no optimized PCB layout. Additionally, they lacked packaging suitable for retail display and shipping protection. Analysis → I evaluated the circuit requirements and identified inefficiencies in component placement that could lead to signal interference and increased board size. On the packaging side, there was no structured dieline or branding layout. Solution → I delivered a compact, efficient PCB layout along with a functional and visually appealing packaging design tailored for both protection and retail presentation. Process → I designed the PCB layout with proper component spacing, trace optimization, and grounding to ensure stable performance. I integrated Arduino-based microcontroller compatibility for easy programming and testing. For packaging, I created a dieline structure with accurate dimensions, ensuring the product fit securely. I also designed the label and box layout to align with the client’s branding and improve shelf appeal. Tools/Skills Used → PCB Design Software, Circuit Design, Embedded Systems, Arduino, Packaging Design Tools Result/Outcome → The PCB functioned reliably during testing with improved efficiency and reduced size. The packaging design was approved for production and enhanced the product’s market presentation, helping the client prepare for retail distribution.

Industrial & Product Design Engineer (3D CAD & Prototyping)

CAD • Freelance

Sep 2024 - Sep 2024 • 0 mos

Client/Company → NovaTech Consumer Products approached me to develop a compact, ergonomic enclosure for a new handheld smart device intended for mass production. Problem → The client had a rough concept but no manufacturing-ready design. Their initial model lacked internal component alignment, proper ventilation, and structural integrity for injection molding. Analysis → I reviewed the concept and identified key issues: poor wall thickness consistency, lack of mounting structures for PCB integration, and no consideration for assembly or material constraints. The design also risked overheating due to limited airflow. Solution → I proposed a complete redesign focused on manufacturability, internal component layout, and durability while maintaining the intended form factor. Process → I started by building a parametric 3D model in SolidWorks, defining precise dimensions for all internal components including PCB placement and battery housing. I redesigned the enclosure with proper wall thickness, snap-fit joints, and screw bosses for assembly. Ventilation slots were strategically added to improve heat dissipation without compromising aesthetics. I also prepared technical drawings and STL files for prototyping and testing. Tools/Skills Used → SolidWorks, Autodesk Fusion 360, 3D Rendering, Mechanical Design Principles, Prototyping Result/Outcome → The final design was successfully 3D printed and tested with zero fitting issues. The client moved forward to manufacturing with a production-ready model, reducing redesign costs and accelerating their product launch timeline.