Product design and development with Rebel Engineering

David Jasiewicz
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  • ENTREPRENEURSHIP
  • EVERY TWO WEEKS

I help first-time physical product founders launch faster and smarter by eliminating costly design and manufacturing mistakes before they ever reach production.

Episodes

  1. 6 APR

    009 The expensive mistake in every overbuilt prototype

    Most people think making a product stronger automatically makes it better, but that’s not always true. In this video, I break down the difference between overbuilding and proper engineering, and why blindly adding strength can actually hurt your design.

    8 min

  2. 2 APR

    008 Engineers vs Mechanics: The Real Problem With New Cars

    Why are modern cars so hard to repair? In this podcast, I break down the real reason behind the tension between engineers and mechanics, and why it’s not as simple as “bad design.”

    12 min

  3. 31 MAR

    007 The Problem with Choosing the Wrong Engineering Major | Engineering vs Engineering Technology

    Engineering vs Engineering Technology, what’s the real difference, and which degree is right for you?

    19 min

  4. 27 MAR

    006 Sunken cause fallacy. Why quitting and starting over is hard

    The sunk cost fallacy can quietly derail engineers, inventors, and product developers. When you’ve invested months (or years) into a design, walking away can feel impossible, even when a better solution exists.

    9 min

  5. 26 MAR

    005 Is Your Product Idea Good? It Must Pass These 5 Tests!

    Have a game-changing product idea but worried no one will buy it? In this video, I break down the 5 real-world tests I’d use to validate a product idea before investing serious time and money based on decades of experience designing, developing, manufacturing, and selling physical products. You’ll learn how to prototype quickly, test demand without looking like a scam, gather meaningful customer feedback, refine your design, and validate pricing for profit. If you’re an entrepreneur, inventor, or engineer preparing to bring a physical product to market, this framework can save you years of effort and thousands of dollars. Topics covered: product validation, prototyping, market testing, customer interviews, pricing strategy, manufacturing readiness, startup product development.

    20 min

  6. 23 MAR

    004 Everyone Gets This Wrong - Overbuilt vs Overengineered

    ✅ Get my free product development Cheat Sheet: 👉 https://shorturl.at/5qSGX ✅ www.rebeleng.us What’s the real difference between overbuilding and overengineering? In product design and mechanical engineering, making something stronger, heavier, or more complex than necessary can quietly ruin usability, cost, and market success. Using real-world examples—from shovels and vacuums to smartphones and failed tech products—this video explains how to design for intent, avoid costly mistakes, and build products people actually want to use. If you’re an engineer, inventor, entrepreneur, or product developer, this is a must-watch before you take a physical product to market. ⏱️⏱️VIDEO CHAPTERS⏱️⏱️ 0:00 — Overbuilt vs. overengineered explained 0:29 — The 30-lb “tank” snow shovel story 1:48 — How engineers might overengineer a shovel 4:41 — Cheap vs. professional-grade tools 5:26 — Why good products still fail 6:47 — The overbuilt Kirby vacuum example 7:36 — The overengineered Dyson teardown 9:01 — What professionals actually use 9:28 — Designing for intent (not extremes) 10:16 — Designing for the 99% vs. the 1% 11:05 — When overbuilding makes sense 12:10 — Quantity, lifecycle, and smart design decisions 👤 Connect With Me On Other Platforms: LinkedIn: / davidjasiewicz Instagram: / rebelengr Facebook: / rebelengineeringanddesign X (Twitter): https://x.com/RebelEngr TikTok: / rebel.engineering For Business Inquiries: info@rebeleng.us

    14 min

  7. 19 FEB

    003 Product design decisions that manufacturers secretly hate

    ✅ Cheat sheet: 👉 https://shorturl.at/5qSGX www.rebeleng.us - SCHEDULE A FREE 15-MINUTE FEASIBILITY CALL In this video, I break down the most common product design mistakes that quietly increase costs, extend lead times, and push your job to the bottom of the priority list. If you're developing a physical product, working with CNC machining, injection molding, casting, or fabrication, this is essential Design for Manufacturing (DFM) knowledge. We cover tight tolerances, sharp internal corners, missing draft angles, undercuts, unnecessary cosmetic finishes, exotic materials, poor assembly planning, and more, plus how to become the kind of customer manufacturers actually want to work with. If you want lower quotes, faster production, and better supplier relationships, this video will change how you design. ⏱️⏱️VIDEO CHAPTERS⏱️⏱️ 0:00 – Why Manufacturers Go Silent 0:27 – Designs Suppliers Quietly Hate 1:01 – How to Read a Manufacturer’s Reaction 2:57 – Designing Without Choosing a Process 4:21 – The Truth About Tight Tolerances 5:50 – Sharp Corners & Why They’re a Problem 7:12 – Ignoring Draft Angles in Molded Parts 8:12 – The Hidden Cost of Undercuts 9:10 – Overdesigning Cosmetic Surfaces 9:58 – Assembly Strategy Mistakes 11:09 – The Power of Standardizing Parts 12:07 – Avoiding Exotic Materials 12:40 – Manual Processes & Automation Risks 13:37 – The Big Problem: Ignoring Manufacturers 14:40 – The 10,000 Unit Reality Check 👤 Connect With Me On Other Platforms: LinkedIn: https://www.linkedin.com/in/davidjasiewicz/ Instagram: https://www.instagram.com/rebelengr/ Facebook: https://www.facebook.com/rebelengineeringanddesign X (Twitter): https://x.com/RebelEngr TikTok: https://www.tiktok.com/@rebel.engineering For Business Inquiries: info@rebeleng.us https://www.patreon.com/RebelEngineering https://buymeacoffee.com/rebelengineering

    16 min

  8. 18 FEB

    002 the harsh reality of scaling your product from prototype to production.

    ✅ Cheat sheet: 👉 https://shorturl.at/5qSGXrebeleng.us - Your top location for product design and development resources. If your prototype worked perfectly on your desk, that’s exactly why it might fail in mass production. In this video, I explain why prototypes lie, and how manufacturing exposes every shortcut you took. We cover the biggest mistakes first-time physical product founders make when moving from prototype to production, including tolerance stackup, material changes, 3D printing vs injection molding, tooling costs, assembly errors, and production speed. A prototype proves an idea. Mass production proves discipline. If you're bringing a physical product to market, this will help you avoid costly rework, blown tooling budgets, and painful manufacturing delays. ⏱️⏱️VIDEO CHAPTERS⏱️⏱️ 0:00 – Why Prototypes Fail in Mass Production 0:52 – The Prototype Confidence Trap 1:12 – Proof of Concept vs Production Reality 2:03 – Variation, Tolerances & Why Parts Stop Fitting 2:29 – 3D Printing vs Injection Molding Problems 3:25 – Assembly Errors in High-Volume Manufacturing4:19 – Tolerance Stackup & Six Sigma Explained 4:44 – Material Changes That Break Working Designs6:54 – Tooling Costs, Undercuts & Manufacturing Risk 10:55 – The Mindset Shift: Design for Learning, Not Completion

    13 min
  9. 001 The $10,000 Product Design Mistake Nobody Talks About

    17 FEB

    001 The $10,000 Product Design Mistake Nobody Talks About

    ✅ Cheat sheet: 👉 https://shorturl.at/5qSGXrebeleng.us - Your top location for product design and development resources. Discover the shocking truth about how a single design mistake can lead to a staggering loss of $10,000. In this video, we'll explore the common pitfalls that can have a significant impact on your bottom line. From user experience to conversion rates, we'll dive into the world of design and reveal the simple mistakes that can cost you thousands. Whether you're a business owner, designer, or simply looking to improve your online presence, this video is a must-watch. Learn how to avoid these costly mistakes and take your design to the next level. Watch now and find out how one simple design mistake can cost you $10,000. ⏱️⏱️VIDEO CHAPTERS⏱️⏱️ 0:00 – Why good product ideas still fail 1:04 – The “simple part” illusion that costs $10k+ 2:29 – How minor details explode tooling costs 3:07 – Why copying designs and snaps breaks products 4:01 – Stop designing without manufacturing input 5:36 – Manufacturing is a design input, not a later problem 6:46 – Tolerance stackup: the invisible production killer 8:47 – Material choices that quietly ruin products 9:14 – Designing parts real humans must assemble 10:31 – Why quotes come back way higher than expected 11:06 – Prototypes lie: 3D printing vs real production 14:37 – The mindset shift that prevents expensive mistakes

    16 min
  • 9 Episodes

About

I help first-time physical product founders launch faster and smarter by eliminating costly design and manufacturing mistakes before they ever reach production.

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