Quilt’s Outdoor Unit (ODU) is the thermal workhorse of the heat pump system and the key to making Quilt the most efficient heat pump in it’s class. In addition to upgrading the thermal sub-systems of a traditional heat pump into the premium category, the Quilt ODU’s architectural design transforms HVAC equipment from eyesore infrastructure into a modern product that both blends into a homes exterior aesthetic and stands out as a statement piece you’d be proud to show your neighbors. Encased in durable powder-coated sheet steel, the design is not only ready for all environmental abuse, but also features careful considerations for installation, service, and maintenance.

Joining the project late in order to help the team solve manufacturability challenges and design custom injection molded enclosures, I ultimately became responsible for the entire mechanical assembly (~30 components) from the final proto builds through to manufacturing and validation testing. After designing and establishing manufacturing plans for all of the exterior components including a complex powder-coated aluminum sheet assembly for the highly-aesthetic front panel and tricky injection molding design for the prominent logo, I led the mechanical engineering efforts through EVT and DVT, while pushing to bring up consumer product-level quality processes and documentation at a traditional HVAC manufacturer in order to deliver the product to production on schedule.