Industrial Designer — DFM & Product Design

Design shaped by the mold,
felt by the user.

Portrait of Kuo Kai Liao

With a solid engineering background in heavy mold manufacturing and high-precision tooling development, I anticipate and resolve mass-production constraints at the concept stage — bridging engineering feasibility (DFM) with refined aesthetics and user experience. My work extends through to production, driving CMF development and cosmetic quality with suppliers and cross-functional teams to ensure design intent is faithfully realized at scale.

Based in
Taipei, TW
Experience
10+ Years
Sectors
Electronics / Advanced Hardware
01

Expertise

Core strength: With a solid engineering background in heavy mold manufacturing and high-precision tooling development, I anticipate and resolve mass-production constraints at the concept stage. This philosophy lets engineering feasibility (DFM) and refined aesthetics bridge naturally — always with user experience at the core.

Cross-industry track record: Spanning premium consumer electronics (ASUS, Ubiquiti) and advanced hardware technology (Tron Future), I turn structurally complex hardware and industrial equipment into products with both refinement and commercial maturity.

Core Skills
SketchAdobe IllustratorSiemens NXKeyshotInnovation Development
Manufacturing
CastingCAD/CAMCNCMold Design
Soft Skills
Vendor ManagementCross-functional Collaboration
AI Tools
VizcomGoogle FlowClaude
02

Experience

01
Principal DesignerHybrid
Tron Future Tech
May 2023 — Present
  • Production quality optimization: Established on-site supplier evaluation protocols to optimize part quality, successfully reducing cosmetic defect rates by 15% and cutting step-and-gap assembly alignment gaps by 10%.
  • CMF & weathering specification: Defined high-performance CMF paint strategies meeting strict UL 746C F1 outdoor standards, eliminating cosmetic defects and structural steps while ensuring IP66 dust/water resistance and UV durability in harsh field environments.
  • Heavy-duty packaging engineering: Re-engineered transport packaging, replacing costly protective cases with custom 10 mm AB waterproof corrugate and precision-cut EPE foam — cutting cost by roughly 90% while still passing defense-grade transport and drop-test standards.
  • Design strategy & award-winning UX: Built a simplified, high-end commercial visual identity that breaks from the rigid lines of traditional defense hardware; ergonomically optimized tactile handles infused forward-looking UX into the product, earning the 2025 Golden Pin Best Design Award.
02
Product DesignerOn-site
Ubiquiti Inc.
Jun 2022 — Jan 2023
  • User experience (UX) optimization: Turned consumer and enterprise networking concepts into market-driven, high-share hardware — ensuring seamless, premium experiences through intuitive and reliable physical deployment flows.
  • Proactive DFM integration: Applied tooling insight to optimize draft angles early and plan precision parting lines with strategic reveal grooves, reducing production steps and tolerance issues while boosting cross-team ME development efficiency by 20%.
  • Cross-functional collaboration: Partnered closely with engineering from early concept development to build functional prototypes, balancing advanced aesthetics with manufacturability to strengthen overall market performance.
03
Senior Industrial DesignerOn-site
ASUSTeK Computer Inc.
Dec 2019 — May 2022
  • Gaming hardware & UX innovation: Leveraged a deep passion for gaming hardware to spot subtle user needs others miss; infused "tech ritual" and emotional connection into structural design from the earliest sketches — winning the key ROG Phone 6 proposal.
  • Advanced CMF rendering & visualization: Specialized in simulating complex film-stack visual effects in high-end renders, translating sketch-stage aesthetic concepts into precise digital visualization for cross-team alignment.
04
Mold Design EngineerOn-site
WUEI CHIUEN INDUSTRY CO, Ltd
Mar 2013 — Nov 2019
  • Mold design & engineering execution: Led multiple high-precision mold design and modification projects, converting complex client needs into clear technical specifications and achievable production targets.
  • Advanced CAD & process optimization: Expert in Siemens NX for high-level concept design and reverse-engineering scans; negotiated with production teams and vendors to optimize manufacturing processes and improve line efficiency.
05
FreelanceRemote
Freelance Designer
Mar 2015 — Present
  • Sheet-metal industrial design & family strategy: Defined cohesive series design language and visual identity for complex heavy sheet-metal machinery, balancing heavy-industry structural constraints with modern high-end aesthetics.
  • International collaboration & DFM: Worked directly with US tech companies and Taiwan heavy-industry leaders (YAMAHA, Takizawa, INNOVA) on front-end UX research, concept development, and parametric prototyping to exact client process specs.
03

Selected Work

A selection of projects successfully driven from concept definition to mass production. You're warmly invited to explore these works in digital form.

Anti-Drone System (T. Jammer) 1
01

Anti-Drone System (T. Jammer)

Tron Future
  • Established a simplified, high-end commercial visual identity that breaks from the rigid lines of defense hardware, with ergonomically refined tactile handles — winner of the 2025 Golden Pin Best Design Award.
  • Defined a high-performance CMF coating strategy compliant with UL 746C F1 outdoor weathering standards, ensuring IP66 dust/water resistance and UV durability.
CMFWeathering EngineeringGolden Pin Award 2025
Anti-Drone System (T. Jammer) 2
NX-1 1
02

NX-1

Tron Future
  • An independently completed reconnaissance drone concept, built in Siemens NX to push G2/G3 surface continuity for aerodynamic flow while maintaining rigorous parametric control.
  • Airframe engineered for additive manufacturing with a split-shell layout, balancing carbon-fiber arm joints against internal electronics packaging constraints.
Siemens NX3D-Printed PrototypeSelf-Initiated
NX-1 2
UX-2000 1
03

UX-2000 see more ↗︎

Takizawa
  • Translated first-hand pain points from years as a machine operator into user-centered industrial design; one of three thematic proposals advanced to final mass production.
  • Analyzed competitor styling trends to precisely define guard-window and overall structural proportions, establishing TAKIZAWA's design DNA.
User InsightCompetitive AnalysisMass Production
UX-2000 2
04

Power Amp see more ↗︎

Ubiquiti
  • Integrated a central linear resonant actuator (LRA) to deliver precise haptic feedback and tuned damping as the dial rotates.
  • Designed an adaptive control scheme that switches between free-spin and detent-vibration modes, keeping the digital interface and physical feedback in sync.
Haptic FeedbackAdaptive ControlHardware UX
Power Amp 2
G3 Touch Enterprise 1
05

G3 Touch Enterprise see more ↗︎

Ubiquiti
  • Optimized the product's signature landscape architecture through extensive physical mockup testing, cross-validated with hand-travel efficiency data.
  • Introduced a new rear-shell geometry that gives the product a fresh visual identity and superior cable management.
ErgonomicsPhysical ValidationData-Driven Design
G3 Touch Enterprise 2
Intercom 1
06

Intercom see more ↗︎

Ubiquiti
  • Focused on fine-tuning enclosure proportions for harmony with architectural surfaces, while precisely calibrating button actuation feedback.
  • Conducted blind tactile tests across multiple engineering samples, strategically holding a 0.5 mm operating gap in the 3D form to absorb production tolerances.
Proportion RefinementTolerance ControlTactile Experience
Intercom 2
ROG × Ubiquiti WiFi 1
07

ROG × Ubiquiti WiFi see more ↗︎

Ubiquiti Design Challenge
  • A timed on-site design challenge during an interview: fuse ASUS ROG's gaming identity with the aesthetic language of Ubiquiti's home networking line.
  • Chose a UFO form and ritualistic lighting to bridge gaming immersion with the perceived stability of networking products; completed within the time limit (not advanced to structural validation).
Timed ProposalBrand FusionConcept Design
ROG × Ubiquiti WiFi 2
ROG Phone 6 1
08

ROG Phone 6

ASUS
  • Flagship model: conceived an active opening mechanism inspired by a supercar's deployable rear wing, turning high-load thermal vents into a premium mechanical ritual.
  • Standard model: a layered-film back cover with vertical light bars and dot-matrix animation simulates a moving logo, evoking supercar speed aesthetics.
Mechanism DesignLighting InteractionGaming Hardware
ROG Phone 6 2
Sketch 1
09

Sketch

ROG Phone 6 · ASUS
  • Hand-drawn and digital sketches from the ROG Phone 6 ideation phase, tracing exploration from opening mechanisms and accessory systems to overall form language.
  • Divergent sketching converged the design direction, enabling rapid communication of form possibilities and mechanical logic at the proposal stage.
Sketch IdeationForm ExplorationDivergent Concepts
Sketch 2
04

Contact

Let's bridge design and manufacturing — together.