Aethermotics

Aethermotics – Lead Designer & Co-Founder (2021–2025)
Wearable Thermal Management System

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At Aethermotics I've led the design of a compact, active cooling system for workers in high-heat environments. Our goal was to create a wearable solution that could fit discreetly under PPE and adjust dynamically to both user and ambient conditions.

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I developed the system architecture and airflow distribution, including bespoke fittings and soft-to-hard interfaces. Prototyping was driven by additive manufacturing, with a focus on transitioning toward scalable DFM and traditional manufacturing methods. I also conducted early-stage customer research and field validation to shape both the product and its deployment strategy.

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This project blended design, engineering, and strategic thinking to bring an ambitious wearable tech platform closer to market readiness.

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Processes:

• CAD for SLS, SLA, FDM, Laser cutting and Folded Steel.

• Heat sealing synthetic garment elements.

• Garment and Pattern Development physically and digitally (Adobe Illustrator, Clo3D)

• CAD optimisation for air flow development and novel air flow conduits and connectors.

• Optimisation for on-body hardware via shape optimisation, anatomical placements and development of weight distribution systems using Lines of Non Extension.

• Developing garments for scale via pattern optimisation for material waste reduction.