Product Design

Where the Physical Product Meets the Digital Experience

We deliver product design, human factors, and UI design within one accountable program alongside your firmware, connectivity, and architecture.

Discuss Your Design Needs
Embedded In Connected Systems

What sets us apart

System-Level Design Thinking
Interfaces designed to work together across devices, mobile, and web.
Constraint-Aware Interface Design
UX shaped from the start for BLE latency, offline modes, and battery life.
Usability as a Safety Control
Critical workflows designed against use errors and failure states early.
One Accountable Team, Device-to-Cloud
Design delivered inside the same program as your firmware, connectivity, and architecture.

Design in connected systems

Design Choices Are System Commitments

An interface can only promise what the system behind it is built to deliver.

A screen that promises instant feedback is making a firmware timing commitment. A sync indicator is making a claim about connectivity architecture. Both are system decisions, and usually they’re made by designers who never touch the system that has to keep them.

We design and build both the interface and the system underneath it, so the promises on the screen are ones we keep.

Pt Teamwork Bluegrey 2
We're a trusted team across your connected system.
Product design Capabilities

From First Concept to the Interfaces That Ship

We support six areas of product design, spanning what the product is, how people use it, and how it gets validated.

Product design starts before there's anything to draw. We help shape early product definition by testing user needs against what the technology can actually deliver, while the product is still cheap to change.
On lean programs this work runs entirely in-house, from first requirements through a functional prototype.
Key Capabilities:
  • User needs translated into device requirements and governing specifications
  • Product design description development
  • Interface definition and control documentation between system components
  • Alignment across stakeholders when client vision and technical partner requirements pull in different directions
  • Concept feasibility assessment against sensing, connectivity, power, and budget constraints
  • Form, fit, and function tradeoffs managed against hard technical requirements
  • Design decisions sequenced so changes cost a revision instead of a rework
  • Functional prototype development with our electronics and embedded teams
  • Investor-ready proof of concept on early-stage budgets
  • Comprehensive design files that protect IP and carry into future development phases
Talk Through Your Program
The experience of a connected product lives in its workflows, what a user does, what the system tells them, and what happens when the connection drops.
We design interactions knowing the technical constraints because we build the systems underneath them.
Key Capabilities:
  • UX discovery, research, and workflow refinement
  • Design thinking applied to new feature ideation and evaluation
  • Product definition refinement through user-facing workflow design
  • Interaction design across scanning, connection, sync, and failure states
  • Honest system-state design so users see what’s synced, what’s pending, and what to do next
  • Information architecture for complex technical workflows
  • One coherent experience across device, mobile, and web touchpoints
  • Patient and clinician interactions designed as a single system
  • Interaction sequences maintained across multiple hardware generations
Talk Through Your Program
Interfaces built against real device constraints, so what ships matches what was designed.
We design and build within the same team, which keeps UI decisions implementable and design systems grounded in what the platform can do.
Key Capabilities:
  • UI design balancing clinical requirements, regulatory constraints, and consumer-grade accessibility
  • Interface design for clarity and speed in technical, high-frequency workflows
  • Design shaped by connectivity states, latency, battery life, and small screens
  • Scalable, lightweight design systems built for long-term product evolution
  • Native platform design systems supporting edge cases and long-term adherence
  • Visual concepts converted into implementable, sequenced development plans
  • Scalable, lightweight design systems built for long-term product evolution
  • Native platform design systems supporting edge cases and long-term adherence
  • Visual concepts converted into implementable, sequenced development plans
Talk Through Your Program
On connected products, the hardware is an interface too. Form factor, control placement, and physical affordances shape the experience as much as any screen.
We handle interaction-level physical design on lean programs, informed by mechanical engineering experience on our team. When a product calls for dedicated industrial design depth, we bring in trusted partners and run the work inside the program.
Key Capabilities:
  • Form factor input during concept and architecture phases
  • Control placement and physical affordance design
  • Physical and digital interactions designed as one experience
  • Interaction design grounded in electronics, enclosure, and manufacturing realities
  • Collaboration across design, electronics, and mechanical disciplines
  • Full industrial design through trusted partners for the most complex and polished products
  • Partner work run inside the program, same requirements, same documentation
Talk Through Your Program
Use-related risk is engineered out early, when it enters the same risk management process as every other program risk.
We integrate usability engineering into system requirements from the first architecture conversations. When a program requires formal validation under IEC 62366-1, we bring in proven partners and run the work inside the program.
Key Capabilities:
  • Usability engineering requirements traced into system requirements
  • Use-related risk managed within the program’s risk management process
  • Critical task and workflow identification where use errors carry consequences
  • Critical workflows designed against use errors and failure states
  • Interaction design tested against real device behavior across hardware generations
  • Formative and summative evaluation through proven HFE partners
  • IEC 62366-1 compliance work coordinated and managed inside the program
  • Partner deliverables integrated into program documentation
Talk Through Your Program
Design iteration shouldn't wait on hardware. We build the tools that let design teams move at software speed on hardware products.
Key Capabilities:
  • Web-based device simulators enabling design iteration without physical hardware
  • Hardware behavior simulation for UI development ahead of device availability
  • Custom tooling that accelerates design cycles at scale
  • Designs tested against real connectivity behavior before implementation
  • Functional prototypes bridging design intent and engineering feasibility
Talk Through Your Program
Product design Capabilities
Icon Product Design Concepting Grey

Definition & Concept Shaping

Product design starts before there's anything to draw. We help shape early product definition by testing user needs against what the technology can actually deliver, while the product is still cheap to change.
On lean programs this work runs entirely in-house, from first requirements through a functional prototype.
Key Capabilities:
  • User needs translated into device requirements and governing specifications
  • Product design description development
  • Interface definition and control documentation between system components
  • Alignment across stakeholders when client vision and technical partner requirements pull in different directions
  • Concept feasibility assessment against sensing, connectivity, power, and budget constraints
  • Form, fit, and function tradeoffs managed against hard technical requirements
  • Design decisions sequenced so changes cost a revision instead of a rework
  • Functional prototype development with our electronics and embedded teams
  • Investor-ready proof of concept on early-stage budgets
  • Concepts, prototypes, and design documentation that support patent filings and carry into future development phases
Talk Through Your Program
Icon Product Design Ux Interaction Grey

UX & Interactive Design

The experience of a connected product lives in its workflows, what a user does, what the system tells them, and what happens when the connection drops.
We design interactions knowing the technical constraints because we build the systems underneath them.
Key Capabilities:
  • UX discovery, research, and workflow refinement
  • Design thinking applied to new feature ideation and evaluation
  • Product definition refinement through user-facing workflow design
  • Interaction design across scanning, connection, sync, and failure states
  • Honest system-state design so users see what’s synced, what’s pending, and what to do next
  • Information architecture for complex technical workflows
  • One coherent experience across device, mobile, and web touchpoints
  • Patient and clinician interactions designed as a single system
  • Interaction sequences maintained across multiple hardware generations
Talk Through Your Program
Icon Product Design Ui System Grey

UI Design & Design Systems

Interfaces built against real device constraints, so what ships matches what was designed.
We design and build within the same team, which keeps UI decisions implementable and design systems grounded in what the platform can do.
Key Capabilities:
  • UI design balancing clinical requirements, regulatory constraints, and consumer-grade accessibility
  • Interface design for clarity and speed in technical, high-frequency workflows
  • Design shaped by connectivity states, latency, battery life, and small screens
  • Scalable, lightweight design systems built for long-term product evolution
  • Native platform design systems that cover edge cases and keep implementation true to the design over time
  • Visual concepts converted into implementable, sequenced development plans
  • Design iteration grounded in real-world user feedback
  • Continuous refinement across releases and hardware generations
Talk Through Your Program
Icon Product Design Physical Grey

Physical Interaction Design

On connected products, the hardware is an interface too. Form factor, control placement, and physical affordances shape the experience as much as any screen.
We handle interaction-level physical design on lean programs, informed by mechanical engineering experience on our team. When a product calls for dedicated industrial design depth, we bring in trusted partners and run the work inside the program.
Key Capabilities:
  • Form factor input during concept and architecture phases
  • Control placement and physical affordance design
  • Physical and digital interactions designed as one experience
  • Interaction design grounded in electronics, enclosure, and manufacturing realities
  • Collaboration across design, electronics, and mechanical disciplines
  • Full industrial design through trusted partners when form, finish, and brand expression are central to the product
  • Partner work run inside the program, same requirements, same documentation
Talk Through Your Program
Icon Product Design Human Factor Grey

Human Factors Engineering

Use-related risk is engineered out early, when it enters the same risk management process as every other program risk.
We integrate usability engineering into system requirements from the first architecture conversations. When a program requires formal validation under IEC 62366-1, we bring in proven partners and run the work inside the program.
Key Capabilities:
  • Usability engineering requirements traced into system requirements
  • Use-related risk is identified and controlled early, inside the same risk management process as every other program risk
  • Critical task and workflow identification where use errors carry consequences
  • Critical workflows designed against use errors and failure states
  • Interaction design tested against real device behavior across hardware generations
  • Formative and summative evaluation through proven HFE partners
  • IEC 62366-1 compliance work coordinated and managed inside the program
  • Partner deliverables integrated into program documentation
Talk Through Your Program
Icon Product Design Tooling Grey

Design Tooling & Prototyping

Design iteration shouldn't wait on hardware. We build the tools that let design teams move at software speed on hardware products.
Key Capabilities:
  • Web-based device simulators enabling design iteration without physical hardware
  • Hardware behavior simulation for UI development ahead of device availability
  • Custom tooling that accelerates design cycles at scale
  • Designs tested against real connectivity behavior before implementation
  • Functional prototypes bridging design intent and engineering feasibility
Talk Through Your Program

How Design integrates

Design Runs Through the Same Development Process as Everything Else

We help to shape the program instead of reacting to it.
Workflow of systems engineering process

Shared Process

Design runs on the same program infrastructure.

User workflows shape system requirements. Usability risks enter the same risk management process as every other program risk. Design rationale gets documented as decisions are made, in the documentation the rest of the program runs on.

Early Tradeoffs

Cross-layer tradeoffs get made once and early.

When an interface decision carries a firmware timing cost or a connectivity dependency, the people who own those layers are already in the room, so the tradeoff gets made once, on purpose.

Backends How We Work Traceable Architecture
Backends In Connected Systems

Added Depth

Specialized depth gets absorbed into the program.

When a program needs formal HFE studies or dedicated industrial design, we bring in proven partners and run the work under the same requirements, risk management, and documentation. You’re never sourcing, contracting, and managing a second vendor yourself.

Want to understand our full development process? Explore how we work across disciplines.
Device-to-Cloud Capabilities

Connected Medical Systems, Engineered As One.

Punch Through can own every discipline, so each is built for the way the others behave inside one program. Explore our capabilities across the disciplines.
Program Highlights

Design Delivered Inside Real Connected Device Programs

Interfaces designed and shipped as part of the systems underneath them, from implantables to consumer wearables.

Programs •
5

A global fashion brand’s smartwatches reached millions of wrists across several product generations, and they were designed to look like watches first.

Under the face they tracked health and activity, moved logs and firmware updates to a phone over Bluetooth, and ran on a battery sized for a fashion case.

For the wearer, that meant a watch chosen for how it looked that still did what a smartwatch does. It also meant pairing with every phone and OS version its wearers owned, each handling Bluetooth its own way, at a scale where a one-in-a-million quirk came up every day.

Connected Consumer Device
Health & Fitness
Post-Market
Design
Electronics
Embedded Software
Mobile Apps
BLE
BLE Optimization
Device Simulators
HIL Testing
Low-Power Design
Miniaturization
Native Android
Native iOS
OTA Updates
PCB Design
Case Study Hero Watchmaker

Inspire® is the first FDA-approved neurostimulation therapy for moderate to severe obstructive sleep apnea.

A small implant stimulates the nerve that controls the tongue in time with the patient’s breathing, and a connected system sits around it, with a Bluetooth remote the patient holds, an app, and a clinician web portal that monitors the implant wirelessly.

For someone who could never live with a mask, that means sleeping with nothing on their face and starting therapy with a click. It also means the system around a Class III implant has moved through several device generations while every implant already placed stays in a body for years, so no part of the system can change without accounting for every implant in the field.

Connected Medical Implant
Pulmonology
Neuromodulation
Post-Market
FDA Class III
FDA PMA Approved
IEC 60601
IEC 62304
Design
Electronics
Embedded Software
Mobile Apps
Security
Systems
Web Apps & Backends
Azure
Backend API
BLE
Clinician Portal
Connectivity SDK
Cross-Platform
Inductive Telemetry
Infrastructure as Code
Legacy Device Support
Mobile Device Management
Patient using the Inspire Sleep Apnea Therapy System, with implantable device, handheld remote, and mobile app display for tracking therapy and sleep duration.

One in ten people lives with persistent tinnitus, the ringing that does not stop.

PNQ Health’s therapy is software. An iOS app delivers personalized sound therapy through ordinary earbuds, and the app itself is what the FDA cleared, as Class II software as a medical device.

For a patient, that means treatment at home, self-guided, with a clinician overseeing it remotely. It also means the app is the entire clinical product, so it has to hold to a medical standard while feeling like something a person opens every day.

Connected SaMD
Audiology
Digital Therapeutics
Post-Market
FDA Class II
FDA 510(k) Cleared
IEC 62304 Class B
Design
Mobile Apps
Design System
FDA Submission Support
MVP Definition
Native iOS
Requirements & Traceability
Secure Data Model
Software V&V
UX & UI Design
Three smartphone screens displaying the PNQ Health tinnitus therapy app, a SaMD solution, with views of the login screen, treatment progress dashboard, and ear selection interface.

A stealth-stage medical startup is developing an implanted neuromodulation therapy that its clinicians can adjust without the patient in the room.

For the patient, that means a therapy that changes when it needs to instead of at the next appointment.

It also means every adjustment travels from a clinician’s screen to a device inside someone’s body, and that path has to be trusted at Class III stakes before anything is implanted.

Connected Medical Implant
Neurology
Neuromodulation
Proof of Concept
FDA Class III
IEC 62304 Class C
Design
Embedded Software
Mobile Apps
Security
Systems
Web Apps & Backends
Backend API
Biosensing
BLE
Clinician Portal
Embedded Algorithms
FDA Premarket Cybersecurity
Human Factors
Interactive Prototyping
Native Android
Remote Follow-Up
Client Grey Stealth Startup
Programs •
4
Global Smartwatch Brand
Case Study Hero Watchmaker

A Fashion Smartwatch Shipped by the Millions

A global fashion brand’s smartwatches reached millions of wrists across several product generations, and they were designed to look like watches first.

Under the face they tracked health and activity, moved logs and firmware updates to a phone over Bluetooth, and ran on a battery sized for a fashion case.

For the wearer, that meant a watch chosen for how it looked that still did what a smartwatch does. It also meant pairing with every phone and OS version its wearers owned, each handling Bluetooth its own way, at a scale where a one-in-a-million quirk came up every day.

Connected Consumer Device
Health & Fitness
Post-Market
Design
Electronics
Embedded Software
Mobile Apps
BLE
BLE Optimization
Device Simulators
HIL Testing
Low-Power Design
Miniaturization
Native Android
Native iOS
OTA Updates
PCB Design
Inspire Medical
Patient using the Inspire Sleep Apnea Therapy System, with implantable device, handheld remote, and mobile app display for tracking therapy and sleep duration.

Sleep Apnea Therapy, Connected From Body to Cloud

Inspire® is the first FDA-approved neurostimulation therapy for moderate to severe obstructive sleep apnea.

A small implant stimulates the nerve that controls the tongue in time with the patient’s breathing, and a connected system sits around it, with a Bluetooth remote the patient holds, an app, and a clinician web portal that monitors the implant wirelessly.

For someone who could never live with a mask, that means sleeping with nothing on their face and starting therapy with a click. It also means the system around a Class III implant has moved through several device generations while every implant already placed stays in a body for years, so no part of the system can change without accounting for every implant in the field.

Connected Medical Implant
Pulmonology
Neuromodulation
Post-Market
FDA Class III
FDA PMA Approved
IEC 60601
IEC 62304
Design
Electronics
Embedded Software
Mobile Apps
Security
Systems
Web Apps & Backends
Azure
Backend API
BLE
Clinician Portal
Connectivity SDK
Cross-Platform
Inductive Telemetry
Infrastructure as Code
Legacy Device Support
Mobile Device Management
PNQ Health
Three smartphone screens displaying the PNQ Health tinnitus therapy app, a SaMD solution, with views of the login screen, treatment progress dashboard, and ear selection interface.

A Tinnitus Therapy SaMD, Concept to FDA Clearance in Months

One in ten people lives with persistent tinnitus, the ringing that does not stop.

PNQ Health’s therapy is software. An iOS app delivers personalized sound therapy through ordinary earbuds, and the app itself is what the FDA cleared, as Class II software as a medical device.

For a patient, that means treatment at home, self-guided, with a clinician overseeing it remotely. It also means the app is the entire clinical product, so it has to hold to a medical standard while feeling like something a person opens every day.

Connected SaMD
Audiology
Digital Therapeutics
Post-Market
FDA Class II
FDA 510(k) Cleared
IEC 62304 Class B
Design
Mobile Apps
Design System
FDA Submission Support
MVP Definition
Native iOS
Requirements & Traceability
Secure Data Model
Software V&V
UX & UI Design
Stealth Medical Startup
Client Grey Stealth Startup

An Implanted Therapy Its Clinicians Configure From Anywhere

A stealth-stage medical startup is developing an implanted neuromodulation therapy that its clinicians can adjust without the patient in the room.

For the patient, that means a therapy that changes when it needs to instead of at the next appointment.

It also means every adjustment travels from a clinician’s screen to a device inside someone’s body, and that path has to be trusted at Class III stakes before anything is implanted.

Connected Medical Implant
Neurology
Neuromodulation
Proof of Concept
FDA Class III
IEC 62304 Class C
Design
Embedded Software
Mobile Apps
Security
Systems
Web Apps & Backends
Backend API
Biosensing
BLE
Clinician Portal
Embedded Algorithms
FDA Premarket Cybersecurity
Human Factors
Interactive Prototyping
Native Android
Remote Follow-Up
Would you like to see additional programs?

Let's Talk About Your Product's Design Needs

Whether you're designing a new connected product, refining existing interfaces, or preparing for compliance, working together starts the same way.
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01
Quick Discovery Call
Share what you're building, timelines, and constraints. We'll confirm fit and the next best step.
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02
Team Consultation
We dig deeper into technical challenges, needs, and where we can add the most value.
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03
Scope & Kickoff
We align on milestones, documentation, and delivery. Then we get moving and keep you informed.
Start a Conversation
Happy to sign an NDA before we get into specifics. We reply within 1-2 business days.

Contact Us

How can we help?

Share a few details about your project or challenge. We’ll confirm fit and the next best step within a couple of business days. NDA available.

Person fotoJason SheardTina Hanley
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