CARRYING CALM ACROSS CONTINENTS
PROJECT
Shiftwave Travel Case
CLIENT
Shiftwave
SERVICES
Product Design + Manufacturing
Shiftwave’s chair delivers deep-tissue pulsed-pressure therapy in a device the size of a compact recliner. Early adopters wanted that experience on the road, but hauling a delicate, tech-packed seat through airports and hotel lobbies was a non-starter. The case had to:
Protect precision electronics against drops, vibration, and wild luggage carousels.
Meet airline regulations to a check-in-friendly footprint.
Scale fast as the startup’s orders snowballed from beta units to nationwide rollouts.
Drawing on years of designing bike travel cases that survive airport conveyors and cobblestone commutes, we translated that know-how into a protective, travel-friendly solution for Shiftwave’s zero-gravity chair. We launched with small-batch production in our U.S. workshop so the startup could iterate quickly and fulfill early orders without delay. As demand accelerated, we transferred tooling to a trusted facility in Mexico, where near-shore proximity preserved oversight while lowering unit cost. Integrating just-in-time manufacturing and holding a lean buffer of finished inventory keeps lead times tight, cash flow healthy, and Shiftwave chairs moving safely from factory floor to wellness sessions worldwide.
As Shiftwave’s volumes continue to climb, we are now guiding a phased transfer of production to Asia, where specialized facilities give us access to high-precision hard-goods tooling, multi-cavity injection molding, and automated assembly cells. The move will let us replace certain sewn components with molded corner armor, structural rails, and integrated latch systems—enhancements that raise impact resistance, simplify setup for the end user, and embed smart-tracking features without adding excess weight. By combining these advanced processes with our established just-in-time framework, we’ll deliver a more robust, technology-rich travel case while maintaining the responsive supply chain that has supported Shiftwave’s growth from day one.
Designed for the US Special Operating Forces, Shiftwave has since been proven effective by professional athletes and trusted by influential individuals and organizations. Their pioneering technology has also been deployed in Ukraine since the start of the full-scale invasion, providing healing and relief for wounded soldiers and traumatized children.