Dear Yaron and IgnitHQ Team
We’re excited about the opportunity to partner with you in bringing Duke into the physical world.
As a young company taking on billion-dollar incumbents, every interaction matters more than it would for a company that already has the market's trust. The larger players in your space can lean on decades of familiarity, but IgnitHQ has the chance to do something they simply cannot, which is give people an experience they have genuinely never seen before.
That is what makes Duke worth getting right.
Duke isn’t just a trade show prop. He’s a physical expression of the intelligence behind the IgnitHQ platform—a character that listens, speaks, and works alongside people rather than replacing them. On the show floor, that feeling has to come through almost immediately, before anyone has read a spec sheet or heard the pitch. People should walk away feeling like they met Duke, not like they saw a robot demo.
Our goal is to design an experience that feels unmistakably IgnitHQ. Every decision—from Duke’s physical appearance and expressive behaviors to lighting, interactions, and hardware integration—should reinforce the same qualities that define the software: approachable, intelligent, capable, and confidently different.
THE CHALLENGE AHEAD
From Platform to Personality
Most software companies only meet a customer through a screen, so the brand has to work hard to feel human at all. IgnitHQ gets a rare chance to skip that step, letting someone meet the platform in person before they have clicked on anything.
The job is bigger than making Duke look good. It is making Duke feel like the dog he is named after, dependable and attentive, never showing off, always listening for what someone actually needs from him. Not cartoonish, and not a security bot doing laps around the booth either. The distinction you drew on our call, a trusted companion rather than a surveillance drone, is really the whole design brief in one sentence, and we intend to hold onto it through every phase of this work.
When every detail, from form and materials to lighting and behavior, works in harmony, Duke becomes more than a robot. He becomes the personality of the platform.
THE THEMES WE HEARD
The key insights shaping our approach
Shape Duke's Character
Duke is more than a robot—it is the physical embodiment of the IgnitHQ brand. We'll explore multiple visual directions to create a distinctive personality that feels approachable, memorable, and unmistakably IgnitHQ.
Design Expression Through Behavior
Through lighting, movement, sound, and interaction, we'll define a behavioral language that makes Duke feel alive—communicating confidence, intelligence, and approachability in every customer interaction.
Ground Every Decision in Reality
Explore ambitious concepts while grounding every decision in the technical realities of the Go2 platform, integration requirements, and production feasibility.
SCOPE
Program overview
Robots are rarely remembered for their appearance alone or their behavior alone. They are remembered when both work together to create a character that feels whole. The Form and Behavior Sprint for Expressive Robotics is Card79's methodology for designing a robot's physical form and behavioral expression as one integrated system. By combining industrial design and interaction design from the very beginning, we develop a personality that not only looks distinctive but behaves in ways that feel intuitive, engaging, and true to the brand.
The program moves across four collaborative phases, from discovery and character definition through concept development, refinement, and a production-ready handoff. Every decision along the way builds toward a robot people instinctively understand, trust, and remember.
the fAB SPRINT PHILOSOPHY
FORM +
BEHAVIOR +
LIGHT +
VOICE +
MOTION
= PERSONALITY
A robot's personality doesn't emerge from its appearance alone. It is shaped by the relationship between form, behavior, light, voice, and motion. When these elements are designed independently, the result often feels disjointed—a friendly shape with mechanical movements, expressive lighting that doesn't match the voice, or behaviors that undermine the character. The FAB Sprint brings these disciplines together from the outset to create a coherent personality that people instinctively understand, trust, and remember.
PHASE 1
Immersion in the problem
Build a deep understanding of Duke's technical constraints, brand, and character before exploring design directions.
ACTIVITIES
Learn about component placements, Ethernet-port location, and mounting options using Unitree's published Go2 Pro spec sheets, reference imagery as well as an onsite Go2 for physical reference.
Create 2-3 moodboards establishing the visual language and distinct personality for Duke.
Explore different LED hardware to explore opportunities for expressive behaviours
Learn more deeply about how people will possibly be able to interact with Duke at tradeshows.
PHASE 2A
Develop Duke Concepts
FAB Sprint 2A explores different physical expressions of Duke, taking into account the multiple physical constraints that need to be coordinated.
ACTIVITIES
Develop 2-3 concept directions/personalities that synthesize the character's form (through sketches + quick 3D mockups), LED eye/expression language, materials, robustness, component placement and mounting mechanics, and possibly voice (if beneficial)
Print scale models (~1:3 scale, quick/rough print, Card79 in-house) per concept direction, so proportion and form can be handled and felt, not just viewed on screen.
Create renderings for each concept to understand materials and details.
Review with client and evaluate the concepts relative to one another.
Gate: IgnitHQ reviews the 2-3 directions and downselects to 1 direction.
1 round of feedback based on the downselection
Refine the selected direction based on client feedback: enclosure form, LED eye/expression language, material and finish (wrap vs. painted)
Implement technical features in CAD including mounting and cable-routing.
Gate: Review the refined direction with IgnitHQ before detailed engineering begins
PHASE 2B
Bring Duke to Life
In coordination with Phase 2A, Phase 2B explores and defines the interactive elements of Duke that bring it to life through lighting, sound, and voice behavior.
ACTIVITIES
Space planning for LEDs, an onboard-speaker tap-off/driver in the head, and cable routing (no separate microphone or camera; existing body-mounted sensors already cover both)
define which inputs willl be triggering the LED behavior language (listening, speaking, idle, alert), working directly with IgnitHQ's Arduino Uno / LED-matrix breadboard;
Deliver a behavior specification and a higher-resolution LED hardware recommendation for IgnitHQ's electronics/firmware team to implement
Curate 2-3 voice direction options for Duke (e.g. TTS persona or voice-actor reference) aligned to the character brief
Test the LED behavior concepts against a Card79 fit-check prototype: how the light actually diffuses, how bright it reads, and how legible the color/pattern is through the dark sensor face and lens material, since this depends on the real shell, not a simulation
Gate: Review LED/voice direction and serviceability approach with IgnitHQ
PHASE 3
Refine & Validate
Bring together the work from Phase 2A and Phase 2B to combine the form and behaviors. Then validate fit, finish, mounting, sensor clearance, weight, balance, and LED visibility.
ACTIVITIES
Finalize the wrap vs. painted finish recommendation and material/finish callouts (white shell, dark sensor face). Card79 can manage pattern development and vendor coordination as an optional add-on to de-risk execution, see Optional Add-Ons.
Finalize the quick-swap head-attach mechanism: target a handful of screws/pins for field replacement
Test print parts in different 3d printed materials
Explore CMF (Color Materials Finish) on the head to match the wrap/paint of the body.
Test the weight, center of gravity/balance, and sensor-clearance with the Go2 Platform.
Refine CAD of the enclosure: mounting strategy, LED/expression detailing, cable routing, quick-swap attach, weight adjustment (if necessary)
Validate the mounting, cable-routing, quick-swap mechanism, LED diffusion/legibility, weight adjustment against 2-3 rounds of Card79-printed fit-check prototypes before CAD locks
Refine the LED behavior spec and placement based on what is actually visible once printed and lit
Select one voice direction from the curated options
Export iteration-ready STL/STEP files for IgnitHQ's in-house print lab to test fit and feel
Gate: Review CAD, finish direction, and weight/balance findings with IgnitHQ
PHASE 4
Finalization & Prototyping Files
Complete the final CAD and deliver prototyping files, behavior specifications, serviceability documentation, and one production-quality print.
ACTIVITIES
Incorporate feedback from IgnitHQ's in-house print-lab iteration
Finalize CAD of the enclosure: mounting strategy, LED/expression detailing, material and finish specification
Produce 1 final, production-quality print from Card79
Document serviceability (quick-swap head attach) and safe trade-show-operation considerations
Gate: Final CAD, prototyping files, LED/voice behavior spec, and finish recommendation delivered and signed off
PHASE 5
Optional Add-Ons (not in base scope)
Expand the base program with additional branding and wrap development. Additional durability testing /drop testing would also extending lifetime.
ACTIVITIES
Body wrap/graphic concept
Concept sketch only, applying restrained IgnitHQ branding to the Go2 Pro chassis
Not production-ready print files
Separate from the base shell's own wrap-vs-paint finish decision above
Wrap template development & vendor coordination
No wrap pattern exists yet for this chassis shape, so the first real wrap attempt is inherently trial-and-error
Card79 test-fits candidate patterns against its own in-house prototype prints (2-3 rounds) before handing off to a vendor for execution
Reduces the risk of paying a vendor more than once to get it right
Vendor execution cost is Vinyl Ink's reference quote, subject to their own re-quote once a real pattern exist
Additional durability/drop testing:
2-3 rounds of drop-testing on 3D-printed prototypes (destructive; a fresh print each round)
Validates the quick-swap head attach and enclosure durability against the known battery-related tip-over scenario
Adjust CAD accordingly based on learnings from each round
LOGISTICS
Budget and Timeline
Timeline
7 Weeks - Note, this timeline can be adjusted to better align with client milestones
Budget
Duke Head Enclosure Program - $34,000 - $43,000
Estimated Expenses for Prototyping (billed at cost) - $1,000 - $2,000
Optional Add-ons
Body wrap/vendor management $1,500 - $2,500;
Durability/drop testing $3,000 - $5,000
LOGISTICS
Deliverables
1-2 aesthetic moodboards
2-3 concept directions (sketches + quick 3D mockups)
1 refined direction: renderings + mounting concept sketch (cable routing, quick-swap attach)
Wrap vs. painted finish recommendation
Mounting and enclosure strategy documentation for the Go2 Pro head platform, including native Ethernet cable routing and quick-swap attach (provisional pending physical/CAD data; see Risks)
Sensor-placement and Ethernet-port desk check against published Go2 Pro reference data
Space planning for LEDs, onboard-speaker tap-off/driver, and cable routing
LED behavior specification mapped to sound/voice states, validated against a physical fit-check prototype for diffusion/legibility, plus a higher-resolution LED hardware recommendation
2-3 curated voice direction options, with 1 selected by IgnitHQ
Iteration-ready CAD/STL/STEP files for IgnitHQ's print lab, plus 1 final production-quality print from Card79
Weight, balance, and sensor-clearance review
Serviceability and safe trade-show-operation notes
OUR CLIENTS
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our work
Selected Robotics Work
From autonomous mobility and warehouse robotics to robot companions, these projects show how we help robotics companies turn technical innovation into products people understand, trust, and adopt.
Our Practice
Experts in Human-Centered Robotics.
We bring together hardware, software, industrial design, interfaces, and human factors to create autonomous systems that people understand, trust, and adopt. From concept through deployment, we help robotics teams transform technical innovation into successful products.
