Physical–digital system · Hardware-constrained UX · Product design
Challenge
Unlike purely digital products, physical therapy devices introduce constraints that directly shape the user experience from power and heat management to input limitations and safety considerations.
Design decisions had to account for manufacturing, assembly, battery systems, thermal behaviour, and real-world usage, while still delivering a clear and usable interface for athletes and practitioners.
My role &
scope
My primary responsibilities focused on the physical product and system integration, working closely with engineers and manufacturers.
This included:
Physical product design and refinement
3D modelling and rendering
Prototyping, testing, and assembly
Supporting on-device UI design
Contributing to early digital discussions where relevant
This project is included to demonstrate system-level thinking and physical–digital integration.
When software
meets physics
In physical products, UX is shaped by forces digital designers rarely deal with heat, power, latency, ergonomics, and safety. My approach focused on designing interactions that respected these constraints rather than fighting them.
Simplicity, predictability, and physical affordances guided decisions across the device and its supporting interfaces.
Changes focused on:
Clearer hierarchy
Reduced visual noise
More predictable interaction patterns
Outcome: Internal measurement showed a reduction of up to 60% in case-organisation time, improving daily efficiency for legal teams.
Promotion EV1 is not a single interface, but a system of interactions across hardware, on-device UI, and mobile control.
Decisions favoured:
Incremental improvement
Stability over novelty
Clear fallback states
The on-device interface was limited by screen size, input methods, and safety considerations. UX decisions prioritised:
Minimal interaction steps
Clear state feedback
Reduced cognitive load during use
Design decisions were informed by hands-on involvement in prototyping, assembly, and testing. Working directly with components, batteries, and casings grounded UX decisions in physical reality.
Outcome
Delivered a coherent physical–digital therapy product
Supported a production-ready hardware system
Gained deep experience designing UX under physical constraints
Impact came from aligning design decisions with engineering realities rather than pursuing visual novelty.
Retrospective
Physical constraints fundamentally shape UX decisions
Systems thinking matters more than screen polish
Designing with engineers improves product realism
Hardware experience strengthens digital judgment
