SOFTGOODS MAGSAFE POPWALLET+

Company
PopSockets, Boulder, CO

Timeframe
2020

Role
Lead Sustainable Product Design Engineer

Project Goal
Develop a MagSafe-compatible wallet designed to compete with Apple's Leather MagSafe Wallet. The project aimed to incorporate sustainable materials under the "PlantCore" umbrella while ensuring durability and usability.

Alternative Leathers

Sourced and tested plant-based and recycled materials—including mushroom, cactus, pineapple, and cotton leathers—in pursuit of a sustainable leather alternative. Led lab and real-world durability testing to assess performance and guide final material selection.

Mechanical Refinement

To reduce wrinkling and stress from compound curves, draw depths and fillet radii were optimized—relieving strain during forming and improving durability and finish quality.

Testing & Validation

Developed and executed a comprehensive testing plan to evaluate durability, user experience, and competitive performance. Real-world user tests identified failure modes missed in lab simulations, leading to design updates like a card-push cutout.

OUTCOME

The final design achieved a premium user experience with superior durability, integrating recycled and plant-based materials without compromising performance.