Quilt Sense Module
Client: Quilt
Duration: January 2023 - December 2024
Role: Product Development Lead / Lead Mechanical Engineer
Design: Mike&Maaike
Phases: Concept, Architecture, Development, EVT, DVT, PVT
Skills: Product Architecture, EE/ME Integration, ID/ME Integration, Sensor and Flex Integration, Manufacturing Partner Management (JDM), Injection Molding, Reliability Testing, Validation Testing
The Sense module is the brain Quilt’s indoor unit, making the heat pump into a high-performing smart home appliance. Featuring room occupancy sensing mmWave radar, ambient light sensing, high-powered processor, and tri-band wireless, the module enables occupancy-based energy saving and connects all rooms of the house together into a smart mesh that allows each room to be controlled within the context of the whole home. Buttons allow for user override to an offline mode, a speaker provides user feedback, and the modular approach with debug port allows homeowners to easily repair or upgrade their systems without requiring installation crews.
As the product development lead for Quilt and lead mechanical engineer on the product, I was responsible for the design and development of the mechanical architecture (~30 components) from concept through to manufacturing and validation testing. Notable challenges with the module include a high-polish, zero-draft injection molded enclosure, precise integration of the radar sensors, and durable design to prevent damage to the sensitive electronics during the HVAC installation process and long-term operation. After developing the product architecture, I lead the program through proto builds, user-facing beta tests, manufacturing partner onboarding, EVT and DVT; navigating demanding time constraints while enabling a full-suite of testing, and delivering a high-quality design to a production PVT build under a year.
Soon after starting with Quilt as an independent consultant to develop the Dial thermostat, I joined full-time as one of the first hires in order to help the startup achieve their product vision and mission to drive the adoption of energy efficient heat pumps through better design. After completing the first round of thermostat prototypes, my role quickly expanded to include leading the Sense module project from architecture through production and later leading the Outdoor Unit (ODU) mechanical engineering. Throughout my two years at Quilt, the company grew from 5 to over 80 employees and our small (but scrappy) engineering team delivered four high-quality, well-engineered products from concept to production in a year and a half.