As the Lead Product Designer for FEROX, I led the design of a sleek, ergonomic human-powered exercise boat that marries form and function. The goal was to create a lightweight, easily transportable watercraft that provides an exhilarating on-water experience while being highly functional and user-friendly. FEROX was designed using durable materials and rotational molding techniques, ensuring a streamlined, easy-to-use, and visually striking product.

The primary challenge of this project was to design a human-powered boat that was both high-performance and ergonomic, while being simple enough for users to transport and assemble solo. Traditional watercraft designs often emphasize either performance or portability, but rarely both. Our task was to strike the right balance, creating a design that would feel as fast and powerful as a performance craft, while remaining lightweight and modular for easy transportation.

Design Strategy & Approach

Leading the design process for FEROX involved an in-depth exploration of ergonomics, aerodynamics, and hydrodynamics. The vision was to create a product that looked as fast as it felt in use, combining sleek aesthetics with practical design elements. My role spanned from user research and ideation to prototyping and final product development, ensuring every decision was grounded in user experience and performance needs.

I began the Research & Ideation portion of the design process by researching hydrodynamic forms and materials commonly used in performance watercraft and tactical gear. Drawing inspiration from nature, I studied fish forms for their natural efficiency in water. Simultaneously, ergonomic research was conducted, focusing on human-powered workout equipment to inform the ideal structure and comfort for users during exercise. This dual focus on form and function drove the ideation process, with several early sketches focusing on how to best combine speed, agility, and stability.

During the Prototyping & Iteration phase, I used quarter-scale foam and cardboard models to test various design configurations. These early models helped identify issues with weight distribution, attachment mechanisms, and overall ergonomics. The boat’s design evolved significantly during this stage, ultimately leading to a two-pontoon structure for increased stability and reduced weight.

The design was then translated into 3D models using Rhino, allowing for precise refinement of the hull shape and structure. These digital models were further rendered in KeyShot for material and color exploration. We also produced an eighth-scale 3D-printed model to validate form and function before full-scale production.

Some of the Key Product Features of FEROX include:

Ergonomically Designed Hull: The hull was rotationally molded, making it lightweight and buoyant. Its slim profile offers both speed and stability, enhancing the overall user experience.

Human-Powered Propulsion: A rotationally molded prop housing allows users to work out their legs while powering the boat. The prop system can be easily raised or lowered, making it user-friendly during different phases of operation.

Modular Pontoons: The pontoons, designed for maximum stability, are made from rotationally molded materials with anti-slip rubber mats. These can be separated into two halves for ease of transportation.

Adjustable Ergonomic Seating: The seat, featuring an injection-molded plastic frame with elastic support and a gel-padded neoprene back, ensures comfort during extended exercise sessions.

Portable Design: The FEROX’s modular construction, including separable arms made from injection-molded plastic and extruded aluminum, makes it easy to take apart and transport.

Waterproof Storage: A removable waterproof neoprene storage bag with taped seams provides safe, accessible storage for personal items while on the water.

FEROX was designed to provide a high-performance exercise experience on the water, while maintaining ease of transport and setup. The combination of ergonomics, hydrodynamics, and user-friendly construction allowed us to achieve the desired balance between speed, comfort, and portability.

Some Key Outcomes include user satisfaction-usability testing indicated that users appreciated the boat’s comfort and ease of assembly. The ergonomic seating and intuitive prop design ensured that the boat could be used comfortably for extended periods, while still delivering a challenging workout. Innovative Modular Design, the modular pontoons and separable frame made FEROX easy to disassemble and transport, appealing to users who wanted a product they could conveniently take with them on trips or store at home. And lastly Visual Appeal- the edgy, sleek design gave FEROX the look of a high-performance watercraft, reinforcing its speed and agility, while the durable materials and finishes ensured long-lasting performance on the water.

FEROX was a valuable opportunity to combine aesthetic design with practical functionality. By leading the product from research through to prototyping and final development, I was able to ensure that the user experience was at the forefront of every design decision. This project deepened my expertise in integrating ergonomic principles with modular product design, balancing both user needs and manufacturing considerations to create a unique and high-performing product. This project reinforced my belief in the power of user-centered design, where form and function come together to enhance the overall user experience.