PHYSIO EQUIPMENT Development

Concept-to-Manufacture Support for a Sydney Startup

Applied Project® partnered with a Sydney-based physiotherapist and emerging startup to develop an innovative piece of physio equipment inspired by both ancient therapy principles and modern product design. The goal was clear: create a cost-effective alternative to premium devices such as the Theragun—without compromising on performance, manufacturability, or user experience.

Project Objective

Design a physio tool that could compete with high-end market leaders while offering:

• Therapeutic performance comparable to premium devices

• A significantly reduced manufacturing cost through simplified engineering

• A unique natural-inspired approach that resonated with wellness-driven consumers

The challenge lay in achieving simplicity, affordability, and effectiveness together—while ensuring the product could be manufactured reliably at scale.

Approach

Our involvement focused on early-stage concept development, delivering complete, manufacturable design data that would allow the startup to advance to production when ready.

Key elements of our design approach included:

1. Simplified Engineering

Using a “keep it simple” philosophy, we minimised the number of components, reduced assembly complexity, and optimised the internal layout to ensure the lowest possible manufacturing cost.

2. Manufacturability at the Core

Every design decision—materials, geometry, tolerances, and component selection—was guided by production feasibility. This resulted in a design that the startup could confidently transition from concept to tooling.

3. Natural-Inspired Concept

Drawing from ancient therapeutic practices, we integrated subtle, natural design cues that differentiated the product from typical mechanical devices and strengthened its wellness-focused value proposition.

4. Iterative Collaboration

We worked closely with the founder through sketches, early ideation, and multiple feedback cycles. This iterative refinement ensured technical feasibility while staying true to the original vision.

Outcome

Although the startup chose not to proceed to production, the outcome was a strong, validated proof-of-concept with a clear path to market. The project delivered:

• A manufacturable design concept ready for further development

• A low-cost structure with strong competitive potential

• A unique hybrid of traditional therapy and modern engineering

• Production insights that highlighted viability and future opportunities

Key Learnings

• Constraints drive innovation: Limited components and tight cost targets led to elegant, efficient solutions.

• Manufacturing early matters: Addressing production from day one prevented downstream redesign and ensured practicality.

• Startup collaboration builds agility: Adapting to evolving goals strengthened communication and design precision.

Visual Development

We produced a suite of concept sketches and 3D renderings showcasing the product’s ergonomic silhouette, natural-inspired elements, and internal simplicity. These visuals helped the founder clearly understand the form, function, and manufacturability of the proposed design.

The PHYSIO EQUIPMENT project remains a strong example of Applied Project®’s capability to transform ambitious ideas into practical, production-ready concepts.
Our experience in constrained design, product innovation, and startup collaboration continues to shape our approach to future wellness and consumer product developments.