President | Chief Design Engineer

With over 14 years in new product development ranging from cosmetic applicators to exploding national defense work, Sam excels at distilling product requirements, ideation, and CAD. No, he still doesn’t want to talk about his 2025 Philadelphia Eagles.

BSME, University of Washington
BS (Communication), Cornell University

VP Engineering & Sales | Chief Project Manager

The son of a manufacturer, Aaron has spent his life bringing new ideas to market. His expertise includes projecting timelines, production methods, cost estimation, and IP evaluation. In his spare time, Aaron brews beer and runs the soccer podcast Outer Roses.

BSME, Portland State University
PMP, Project Management Institute

VP Accounting | Chief Lab & Testing Engineer

A U.S. Marine Corps veteran and 3D printing guru, Wayne’s prototyping skills are unmatched: machining, CNC programming, woodworking, electronics, logic controllers, and more. When he’s not busy fostering puppies, Wayne volunteers as a certified hunting instructor.

BSME, University of Wisconsin Milwaukee
MBA, University of Wisconsin Milwaukee

DESIGN & PROCESS UPDATES — Ultralight’s engineers found new applications for L’Oreal’s legendary facial cleansing technology and increased the portfolio’s cleansing efficacy with new designs, materials, and production techniques. We collaborated with L’Oreal’s existing manufacturing partner to create novel injection molding techniques and a common product architecture that could be reinterpreted as needed—and made millions of times over.

PATENT EXPLORATION — Our team designed from scratch a new type of neck rehabilitation device that uses electric eddy currents rather than weight to provide muscle-building resistance. We constructed a prototype device from laser-cut, machined, and 3D-printed materials for initial evaluation and user testing. OWL was awarded multiple USPTO patents for this work and used the design as part of its Stage 1 and Stage 1 Extension SBIR grant applications.

DEMONSTRATOR KIT — Early-generation helicopters twitch each time the main rotor passes above the tail boom. The project’s sponsor wanted to retrofit remaining airworthy Cobras for more stable flight. Ultralight engineers created a demonstrator kit based upon a shape derived from computational fluid dynamics. We built a faring from sheet metal, machined aluminum, and COTS pieces that attaches to existing rivet patterns on the tail and rotates open for inspection of the tail rotor drive shaft.

TEST FIXTURE — Microsoft needed a way to test the robustness of its gaming devices for people with low mobility. Ultralight engineers used inexpensive, 3D-printed parts, programmable logic controllers, and pneumatic actuators to create a fixture that cyclically interacts with the controller’s 20+ connection ports.

SIMPLIFICATION — Mantix wanted a fail-proof pully for weekends in the bush, so Ultralight designed a sheave-less double-pulley that is machined from a single solid block of 6061-T6 aluminum. By eliminating failure-prone parts, Ultralight reduced both cost and the opportunity for breakage. This compact, versatile load-management has four different load paths and is designed for use with 550 cord.

R&D PROTOTYPES — A ground-up redesign of RYCA’s pneumatic brushing technology ensured that users could comfortably brush their teeth in a quarter of the time and with 4X the efficacy. A fleet of looks-like/works-like prototypes made from 3D-printed and injection-molded materials were used for clinical and user testing that clinched further investment.

DESIGN & INTEGRATION — Behind the scenes, many hydraulics mechanisms need their fluid supplies to be actively managed. Ultralight engineers created this automated hydraulic supply for just such as purpose. We spec’d off-the-shelf electronics, controllers, power supplies, and hydraulic actuators, then assembled them with bespoke wire-routing and sheet metal design.

COST-REDUCTION — HySecurity wanted to update the design and lower the production cost of a caster wheel used in its high-end retractable fencing products. Ultralight engineers created a 2K wheel assembly, with urethane tread shot over a die-cast aluminum hub.

PROOF OF CONCEPT — PreAct Technologies needed a soda can-size device to test its novel automotive collision detector and appeal to potential partners. Ultralight squeezed eight IR LEDs, photo detectors, PCBAs, a power supply, and connectors into a great-looking anodized aluminum case that could both mount to a camera tripod and efficiently dissipate immense heat energy.

DESIGN EXPLORATION — Our client wanted to improve evacuation from fishing vessels. After extensive interviews with rescue swimmers, boat captains, survival trainers, and others, we invented a specialized ascender to prevent evacuees from being swept away by wind, waves, and currents as they swim to lifeboats. We built a simple prototype from machined aluminum and COTS components for in-pool testing and evaluation.

JUST FOR FUN — Sam wondered if he could cook a hot dog with sunlight. His one-meter-wide, 16-panel dish concentrates 40X the amount of solar energy a hot dog might normally see onto its central axis, making a pink hot dog glow white in a matter of moments. He recommends 5-6 minutes for optimal juice burst.

DYI KICKFLIPS — Wayne wanted to see if he could create a cheap mold for skateboarders to 3D print and use at home. He did! His creation allows anyone to clamp glued plywood into a classic, full-size, multi-angled board contour for shaping and curing.

Stringing a bow is part art, part brawn. This simply-designed bow press allows…