Orion Sleep System

Helped Orion bring its first hardware product to market by turning a premium sleep-system vision into a manufacturable, production-ready product.

Orion · 2025-2026 · Product development, design engineering, manufacturing support

Challenge
Orion had a strong product vision but no full-time hardware engineering team. To launch its first physical product, the team needed senior mechanical product development support that could move quickly across design, engineering, suppliers, and manufacturing.

The product was technically demanding: airflow, thermal performance, internal packaging, material execution, reliability, and production quality all had to come together in a product that felt refined enough to belong in the bedroom.

Approach
As part of a small mechanical engineering team assembled for the program, I helped turn Orion’s product vision into a buildable, manufacturable system. We worked closely with the industrial design team so the exterior form, airflow strategy, internal packaging, and manufacturing approach evolved together.

My role spanned product architecture, airflow strategy, prototype validation, manufacturing support, early production oversight, and root-cause problem solving under a compressed startup timeline.

Outcome
Orion launched its first hardware product as a refined smart sleep system with the technical performance of a thermal product and the presence of a premium residential object.