The direct answer

A small product-development project can reveal the same core pattern as a larger program: define the desired behavior, prototype the geometry, observe the real flow, and revise the design based on physical evidence.

Key points covered

  • Translate a user goal into measurable physical behavior.
  • Use rapid prototypes to expose flow and geometry problems.
  • Let real testing drive the next design iteration.

Experience behind the lesson

I’m Charles McNall, an engineer, inventor, and exited founder with 18+ years in medical devices, automation, robotics, manufacturing, and physical-product startups. I co-founded Chuck Rack, led product development and commercialization, reached $250,000 in first-year sales, and completed a founder exit in 2024.

Full video transcript

Transcript: What Can a Coffee Blending Nozzle Teach About Product Development?

This is the complete timestamped transcript generated from the video captions. It has been formatted for readability but not rewritten. Automated captions can contain transcription errors; use the embedded video as the authoritative source.

[0:00] hey there and today we're going to talk

[0:02] about something from the project

[0:04] archives so we're going to talk about

[0:07] one of my first

[0:08] projects and since we just talked about

[0:10] provisional patents we'll bring that in

[0:12] too so the idea

[0:15] was how can you make coffee that comes

[0:19] out of a coffee decanter you know the

[0:21] style where you basically just pop it

[0:23] and pour it out into a cup how can you

[0:26] make that have more of a Crema on top

[0:28] like you get in an

[0:30] espresso and so I had a cooworker who

[0:33] was really into this I actually didn't

[0:34] even drink coffee at the time but ended

[0:37] up starting to drink it during this

[0:39] project and haven't stopped

[0:41] since

[0:43] and we had to come up with a a few

[0:46] different ideas basically how can

[0:48] you froth something and we had a few

[0:51] different methods so I'm going to bring

[0:52] up some photos here so the first

[0:57] method was to B basically

[1:03] use

[1:06] a Ultrasonic toothbrush and by putting

[1:09] it in there and frothing it up you ended

[1:11] up getting quite a bit of head on there

[1:13] which is pretty

[1:15] impressive um but at the time that was

[1:18] kind of a complicated method so we

[1:20] actually thought about something a

[1:22] little bit more tried and true which is

[1:25] can we

[1:26] put uh a blender attach on the end so

[1:31] let's look at what I had here

[1:35] for how do I

[1:41] rotate I don't know either

[1:45] way um here we

[1:50] go Ah that's it how do

[1:54] we add a blender attachment so we had a

[1:57] motor and basically had a coupler

[2:00] and then a tiny little

[2:02] blender wheel on there like you get you

[2:05] know on any frothing wand and then a

[2:09] little screen at the bottom to screen

[2:13] out the bubbles to make them all a

[2:15] similar size we found that if you didn't

[2:17] do that you ended up with all sorts of

[2:19] bubbles plus then the coffee came out

[2:21] too quickly so all in all we ended up

[2:24] creating this little guy which isn't too

[2:27] big it would fit right on the end of a

[2:29] cter and then you know could

[2:33] be lithium ion powered although that

[2:36] wasn't really much of a thing back then

[2:39] and overall just make your regular drip

[2:42] coffee taste substantially better and so

[2:45] you know here it was on the end of a

[2:47] decanter that we had and then you know

[2:50] depending on the speeds that you'd have

[2:52] it blending at it could make a pretty

[2:56] decent head on your coffee it also

[2:58] cooled your coffee down substant

[2:59] eventually made it easier to drink

[3:02] so it was a kind of unique thing this

[3:05] predated the

[3:08] um espresso that kind of

[3:12] Blended uh the Nespresso pot up I forgot

[3:15] what that was called but this was also

[3:18] back during the first defile days for

[3:21] patents and so we really wanted to make

[3:23] sure we had lab notebooks that were

[3:26] signed and dated so fine yep so these

[3:29] are all in a lab notebook signed

[3:33] dated and uh you know I would basically

[3:37] make sure that everything was um you

[3:40] know nice and tight in terms of Ip at

[3:43] that time but like I said in the

[3:45] provisional patent application so what's

[3:47] the rest of the story with this so this

[3:49] is where it gets into a more more fun

[3:52] sort of story here in terms of lessons

[3:54] learned so we we had this idea and so

[4:00] neither my friend nor I knew how to

[4:02] write up provisional patents and so we

[4:04] knew one person who was pretty good at

[4:06] IP at the time and did it for the

[4:08] company he worked for and so we paid him

[4:13] $3,000 and he wrote us up a provisional

[4:16] patent application we still had to give

[4:18] him all the

[4:19] drawings and a lot of the words for it

[4:24] and I I think we even had to file it

[4:28] ourselves and so I don't know what we

[4:30] really paid $3,000 for but we did and so

[4:33] then once we had our patent provisional

[4:35] Patent filed we uh thought great now

[4:39] let's go make some money and so we go to

[4:43] the uh us restaurant trade show and all

[4:47] the restaurant equipment is there and

[4:50] went and tried to basically talk with

[4:53] all these companies and see if they'd be

[4:54] interested in this turns out it wasn't

[4:56] really the right

[4:57] show um and also turned out the partner

[5:00] I was with wasn't as much of a sales guy

[5:03] the same as I'm not much of a sales guy

[5:06] and so between the two of us we

[5:09] basically ended up walking around the

[5:10] show and drinking a bunch of coffee and

[5:12] granted we spent another three grand

[5:14] going to the

[5:15] show

[5:17] and so overall this little project ended

[5:20] up going nowhere because of lack of

[5:23] sales experience and being able to sell

[5:25] the idea to the right

[5:27] company um if I to do this again what

[5:30] would I do differently well there's a

[5:32] lot more options now in terms of you

[5:35] could assuming there's something that

[5:37] you can patent and it doesn't infringe

[5:39] on anything I haven't done a search in

[5:40] ages on it but you could probably again

[5:45] put out a

[5:47] little uh decanter tip that's lithium

[5:50] ion powered or what I actually wanted to

[5:52] do if we look on this next

[5:54] page was I wanted to make a funnel if

[5:59] you you guys can see this where the

[6:02] motor's up top and you basically just

[6:04] pour your coffee through and it has some

[6:08] baffles perhaps and maybe a filter but

[6:12] you would stick it on top of your cup

[6:14] and you would just pour your coffee

[6:15] through and it would froth it up and

[6:17] make it you know a lot more fully bodied

[6:21] so either way that's the uh crem funnel

[6:26] from the uh startup Chuck archives and

[6:30] hope you liked

[6:33] it