How To Invent: My 30 Year Innovation Process.

The Quiet Discipline Behind Innovation

Take a Snap Shot

Part of the invention and design process is constant iteration—tweaking, modifying, refining, and occasionally convincing yourself that this version is definitely the final one.
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In reality, you’ll often disappear down rabbit holes that lead absolutely nowhere. Unfortunately, you usually only realise this after you’ve invested several hours—sometimes days—enthusiastically pursuing an idea that turns out to be… not it.

This is all part of the process. And oddly enough, it’s rarely wasted effort. More often than not, you emerge with a better understanding of the problem, only to discover that what you had two versions ago was actually better anyway.
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This is why some form of version control is essential. Being able to step back to a previous iteration can save both time and sanity, and allows you to take a different route without starting from scratch.

Of course, in the excitement of designing, it’s remarkably easy to forget what you did, what you changed, or whether you ever saved that version at all.
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At the very least, save the assembly. Zip it up. Put it in a clearly named folder. Better still, use a proper PDM system within your CAD software—which most companies have anyway.

‍The irony, of course, is that when you’re truly “in the flow”, that’s often when you forget to hit save.
Design may be about creativity and inspiration, but it’s also about being kind to your future self—who will definitely want that file back

Where Did I Put That ?

When you’re designing or inventing, you’ll generate a huge amount of material—concepts, sketches, CAD iterations, spreadsheets, calculations, test results, reference images, websites, videos, and half-formed ideas that only make sense at the time you created them.
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The problem is that ideas move far faster than documentation. If you don’t capture what you’ve done as you go, it’s remarkably easy to lose valuable work, forget why a decision was made, or struggle to reconstruct the thinking months later.

And at some point, you will need to go back and reference it.
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This becomes especially important when creating design history documents, which are often a formal requirement in regulated industries such as medical product development.

Suddenly it’s not just what you decided that matters, but when, why, and what you considered at the time. Your future self—or a reviewer, auditor, or regulator—will want evidence, not just confidence.

Why Traceability Is Non Negotiable.

Traceability is one of those disciplines in product development that feels optional—right up until the moment it becomes absolutely critical.
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Medical product development, in particular, is exceptionally rigorous, and for good reason.

It instils habits that are invaluable in any industry.

Knowing exactly what you’ve tried, when you tried it, and why, is far better than relying on vague recollections or assumptions.
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In medtech, traceability isn’t a “nice to have” — it’s a must-do.
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Believe me, I’ve been there. It’s a mistake you only make once.
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Trying to trawl through old emails and boxes of samples months later is no fun at all.

From early prototypes through to final production, keeping clear records of what was tested, when, and why is essential.

You NEED to specify exact samples used, material certifications, part revisions, software or firmware versions, test dates, and the rationale behind key design decisions.
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When a product moves toward regulatory approval, traceability stops being an internal “nice to have” and becomes a formal requirement.

Regulators (and to conform to your companies design process) don’t just want to see that testing was done; they want to verify exactly what was tested and confirm it corresponds to the approved design. If you can’t clearly link test results to specific versions of parts, materials, or assemblies, the credibility of the entire submission can be questioned.
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The simplest way to avoid this pain is to capture documentation as you go. Store drawings, test reports, certificates, photos, emails, and notes in a proper document management system from day one.

Name files consistently, record revision history, and log changes as they happen. It takes minutes at the time—and saves weeks later.
Trying to reconstruct this information a year down the line is a nightmare.

Prototypes blur together, files go missing, and subtle version changes become impossible to identify. Good traceability isn’t bureaucracy—it’s insurance for your future self and your product.

I Need That Presentation Tommorrow

For this reason, one of the most useful tools in my workflow is a good screen capture application. Being able to instantly grab a screenshot of a spreadsheet, a CAD screen, a website, a document, or even a video means ideas don’t slip through the cracks.

You QUICKLY capture the moment, the context, and the state of the design exactly as it was. I find its better to over capture, just in case.
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This isn’t a paid advert, but Snagit is probably the single most important piece of software I use. I love it. It automatically saves every capture into neatly organised, date- and time-labelled folders, which means you can reliably find something you worked on seven months ago—assuming you remember roughly when you were clever.

Equally important is having a central place to share and organise this information across the entire project team. Tools like Confluence work extremely well for this. They allow you to quickly paste in screenshots, add context, link related work, and build a living record of the project as it evolves.

Instead of knowledge living in someone’s head—or buried in a personal folder—it becomes accessible to everyone who needs it.
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This is particularly powerful when team members join or leave a project, or when someone inevitably asks, “Why did we do it this way?” six months later. With a shared knowledge base, the answer is usually already there.
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All of this also makes producing reports and presentations far easier—which is a given in almost any project. Rather than trying to recreate old visuals or rely on memory, you can simply pull the original captures and show exactly what existed at the time.

Being able to quickly capture—and more importantly, retrieve—saved information is essential.
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Invention may feel chaotic and creative in the moment, but good documentation quietly runs alongside it.

Think of it as leaving breadcrumbs for you and for everyone else on the project—who will be very grateful you did.

Next - Patenting and Protecting Your Idea

How to Invent: My 30-Year Process from 100+ Patents

A Design Engineer's Proven System for Generating Patentable Ideas

After 30 years as a design engineer and accumulating over 100 patents working with companies like DeWalt, Black & Decker, Stanley, and ResMed, I've developed a systematic approach to invention that anyone can learn. This isn't theory from an academic textbook—it's a real-world process refined through thousands of hours creating products that people actually use.

My Personal Invention Process: How I Generate Patentable Ideas

Invention isn't magic. It's not about waiting for inspiration to strike. It's about having a reliable system you can deploy whenever you need innovative solutions. Here's the exact process I use when I need to invent something new:

Step 1: Define the Problem Clearly

Most failed inventions start with a poorly defined problem. I spend significant time understanding exactly what needs to be solved. Questions I ask:

What is the user trying to accomplish? (Jobs-to-be-Done framework)
What are the current solutions and why do they fail?
What constraints exist? (Cost, manufacturing, materials, regulations)
What would the ideal solution look like?
Who benefits if this problem is solved?

Step 2: Research Existing Solutions and Patents

Before inventing anything, I thoroughly research what already exists. This includes:

Patent searches on USPTO, Google Patents, and EPO databases
Competitive product analysis
Academic research and technical papers
User reviews and complaints about existing products
Adjacent industries that might have solved similar problems

This research phase prevents reinventing the wheel and often reveals gaps in existing solutions where new patents are possible.

Step 3: Apply Systematic Innovation Techniques

This is where the real invention happens. I use proven ideation techniques that force your brain to think differently. These aren't random brainstorming sessions—they're structured methods that consistently generate patentable concepts.

The Innovation Tools I Use Daily

SCAMPER Technique for Invention

SCAMPER is my go-to technique for product improvement and invention. It's an acronym that prompts you to think about products in seven different ways:

Substitute: What materials, components, or processes could be replaced?
Combine: What features or products could be merged together?
Adapt: What could be adjusted to serve another purpose?
Modify: What could be changed in size, shape, or attributes?
Put to another use: How could this serve a different market?
Eliminate: What could be removed to simplify?
Reverse/Rearrange: What if the sequence was different?

Real Example: When designing cordless power tools, SCAMPER led me to question battery placement (Rearrange), combine tool functions (Combine), and eliminate unnecessary weight (Eliminate). Several patents came from this single SCAMPER session.

TRIZ: The Russian Innovation System

TRIZ (Theory of Inventive Problem Solving) is based on analyzing millions of patents to identify patterns in how problems are solved. It includes 40 Inventive Principles that provide specific strategies for overcoming technical contradictions.

Key TRIZ Principles I Use Most:

Segmentation: Divide an object into independent parts
Taking Out: Extract the disturbing part from an object
Local Quality: Change structure from uniform to non-uniform
Asymmetry: Change from symmetrical to asymmetrical
Merging: Bring closer together identical or similar objects
Universality: Make an object perform multiple functions
Nested Doll: Place one object inside another
Beforehand Cushioning: Prepare emergency means beforehand

Real Example: TRIZ's "Nested Doll" principle inspired telescoping handle designs. "Beforehand Cushioning" led to safety features that activate before accidents occur.

Morphological Analysis for Complex Products

When inventing complex products with multiple variables, I use Morphological Analysis. This technique breaks down a product into its essential functions, lists alternative ways to achieve each function, and systematically combines them to create new concepts.

Example Process:

List all functions (power source, user interface, safety mechanism, etc.)
Identify 3-5 alternatives for each function
Create a matrix of all possible combinations
Evaluate promising combinations for feasibility and novelty

This method generated over 200 conceptual variations for a single power tool project, with 15+ becoming patentable designs.

Design Thinking Process

Design Thinking provides a human-centered framework for innovation. The five stages are:

Empathize: Deeply understand user needs through observation and interviews
Define: Frame the problem from the user's perspective
Ideate: Generate numerous solutions without judgment
Prototype: Build quick, low-cost models to test concepts
Test: Get real user feedback and iterate

Design Thinking is particularly valuable when inventing consumer products where user experience is critical.

Formula One Innovation Methods

Formula One teams are masters of rapid innovation under extreme constraints. I've adapted their methods:

Marginal Gains: Make tiny improvements everywhere
Rapid Iteration: Test, learn, improve, repeat quickly
Data-Driven Decisions: Measure everything, trust the numbers
Cross-Functional Collaboration: Break down silos between departments
Constraint-Based Innovation: Use regulations as creative challenges

This approach is excellent when you need continuous improvement rather than breakthrough innovation.

Six Thinking Hats Method

Edward de Bono's Six Thinking Hats helps evaluate ideas from different perspectives:

White Hat: Focus on data and facts
Red Hat: Consider emotions and intuition
Black Hat: Identify risks and problems
Yellow Hat: Explore benefits and optimism
Green Hat: Generate creative alternatives
Blue Hat: Manage the thinking process

This method prevents groupthink and ensures thorough evaluation of invention concepts before investing in prototypes.

Systematic Inventive Thinking (SIT)

SIT is a streamlined version of TRIZ focused on five thinking tools:

Subtraction: Remove essential components and adapt
Multiplication: Copy components with modifications
Division: Separate product into independent parts
Task Unification: Assign new tasks to existing components
Attribute Dependency: Create new relationships between attributes

SIT is particularly effective for incremental innovation and product line extensions.

Step 4: Generate Multiple Concepts

I never stop at the first idea. Using the techniques above, I typically generate 20-50 concepts for any given problem. Quantity leads to quality in invention—the 47th idea is often better than the 1st.

My concept generation rules:

No judgment during initial ideation
Combine techniques (SCAMPER + TRIZ often works well)
Sketch everything—visual thinking reveals new possibilities
Take breaks—solutions often emerge while away from the desk
Document everything—today's rejected idea might solve tomorrow's problem

Step 5: Evaluate and Select Concepts

After generating concepts, I use a structured evaluation process:

Patent Novelty: Is it truly new? (Patent searches)
Technical Feasibility: Can it be manufactured with current technology?
Cost Viability: Will target customers pay enough to make profit?
Market Need: Does it solve a real problem people care about?
Competitive Advantage: Why is this better than existing solutions?
IP Protection: Can it be protected with patents?

I score each concept on these criteria and focus resources on the highest-scoring ideas.

Step 6: Build and Test Prototypes

Paper concepts mean nothing until they're tested in the real world. I build prototypes as quickly and cheaply as possible:

Foam Core Models: For form and ergonomics
3D Printed Parts: For mechanical function testing
Breadboard Circuits: For electronics validation
Cardboard Mockups: For user interaction studies
Functional Prototypes: For real-world performance testing

Every prototype teaches you something. Failed prototypes are often more valuable than successful ones because they reveal what doesn't work.

Step 7: File Patent Applications

Once I have a proven concept, I work with patent attorneys to protect the intellectual property. Key patent strategies:

Provisional Patents: File early to establish priority date
Broad Claims: Protect the core concept, not just one embodiment
Multiple Variations: File continuations covering different implementations
Design Patents: Protect unique visual appearance
International Filing: Protect in key markets (US, EU, China)

Real Innovation Stories from My Career

Power Tool Battery Innovation

Challenge: Users complained about battery placement interfering with balance and visibility. Using SCAMPER's "Rearrange" principle, I experimented with unconventional battery locations. This led to a patent for a slide-on battery pack that improved tool balance and allowed hot-swapping without stopping work.

Dust Collection System

Challenge: Traditional dust collection added bulk and cost. Using TRIZ's "Taking Out" principle, I separated the dust collection from the tool body. The result was a modular system that could be added or removed based on user needs—three patents emerged from this approach.

Ergonomic Handle Design

Challenge: One handle design can't fit all hand sizes comfortably. Morphological Analysis helped me map out all possible grip variations. By combining adjustable angle, removable components, and texture variations, I created a handle system that adapts to different users—resulting in five related patents.

Medical Device Safety Feature

Challenge: Needed to prevent accidental activation of medical equipment. TRIZ's "Beforehand Cushioning" principle suggested anticipating the error condition. This led to a sensor-based system that detects incorrect setup before activation—a critical safety innovation that became a key patent for ResMed.

Common Invention Mistakes to Avoid

Falling in love with your first idea: Generate many alternatives before committing
Ignoring patent research: Don't waste time reinventing existing solutions
Over-complicating: Simple solutions are often better and more patentable
Forgetting manufacturing: Brilliant concepts fail if they can't be made economically
Skipping user testing: Your assumptions about user needs are probably wrong
Poor documentation: Keep detailed records for patent applications
Waiting for perfection: File provisional patents early to establish priority

The Innovation Mindset

Beyond techniques and processes, successful invention requires a particular mindset:

Curiosity: Always ask "why" and "what if"
Persistence: Most ideas fail—keep generating and testing
Observation: Watch how people actually use products
Cross-pollination: Solutions from one industry often work in another
Embrace constraints: Limitations force creative solutions
Learn from failure: Every failed prototype teaches valuable lessons
Collaborate: Other perspectives reveal blind spots

Tools and Resources I Use

Patent Databases: USPTO, Google Patents, Espacenet (EPO)
CAD Software: SolidWorks, Fusion 360 for 3D modeling
Sketching: Always carry notebook for quick concept capture
Prototyping: 3D printer, basic workshop tools, electronics lab
Innovation Software: Mind mapping tools, TRIZ databases
Literature: Technical journals, patent analysis, competitive intelligence

How to Start Your Invention Journey

If you're new to inventing, here's how to begin:

For Beginners:

Take the Creative Personality Test: Understand your natural innovation style
Start with SCAMPER: It's the easiest technique to learn and apply
Choose a simple problem: Don't start with complex inventions
Generate 20 ideas: Force yourself past the obvious solutions
Build a rough prototype: Even cardboard mockups teach valuable lessons
Search existing patents: Learn what's already been done
Join inventor communities: Learn from experienced inventors

For Intermediate Inventors:

Learn TRIZ fundamentals: Study the 40 Inventive Principles
Try Morphological Analysis: For complex multi-variable problems
File a provisional patent: Protect your best concepts early
Build functional prototypes: Move beyond appearance models
Conduct user testing: Get real feedback from target users
Study successful patents: Analyze how others protected similar inventions

For Advanced Inventors:

Combine multiple techniques: TRIZ + SCAMPER + Design Thinking
Build patent portfolios: Multiple related patents create defensible positions
Work with patent attorneys: Professional help maximizes protection
Consider licensing: Don't just invent—commercialize your IP
Mentor others: Teaching reinforces your own innovation skills

InventionPath Tools and Resources

I've created interactive tools based on the techniques I use daily:

SCAMPER Idea Generator: Step-by-step prompts using the SCAMPER technique
TRIZ Problem Solver: Apply the 40 Inventive Principles to your challenges
Morphological Analysis Tool: Systematically explore concept combinations
Design Thinking Guide: Structured process for human-centered innovation
Six Thinking Hats Evaluator: Assess ideas from multiple perspectives
SIT Technique Generator: Apply Systematic Inventive Thinking methods
Patent Strategy Generator: Get personalized patent filing strategies
Creative Personality Test: Discover your innovation style (Visionary, Builder, Explorer, or Harmonizer)
Formula One Innovation Methods: Apply F1 rapid iteration techniques

Frequently Asked Questions About Inventing

How long does it take to develop a patentable invention?

It varies dramatically. Simple improvements might take weeks, while complex systems can take years. My average is 3-6 months from initial concept to provisional patent filing, including multiple rounds of prototyping and testing.

Do I need an engineering degree to be an inventor?

No. Some of the best inventions come from people experiencing problems firsthand. Engineering knowledge helps with feasibility and prototyping, but creativity and persistence are more important than formal education.

How much does it cost to file a patent?

Provisional patents cost $130-$280 for USPTO filing fees. Full utility patents with attorney help typically cost $8,000-$15,000. Design patents are cheaper at $2,000-$4,000. International filing multiplies these costs significantly.

Which innovation technique should I start with?

SCAMPER is the easiest for beginners. It's intuitive, requires no special training, and immediately generates ideas. Once comfortable with SCAMPER, add TRIZ for more systematic problem-solving.

How do I know if my idea is patentable?

Search existing patents on USPTO and Google Patents. Your invention must be: (1) Novel - truly new, (2) Non-obvious - not a predictable combination, (3) Useful - serves a practical purpose. Consult a patent attorney for definitive answers.

Should I build a prototype before filing a patent?

You don't need a working prototype to file a patent, but I strongly recommend it. Prototypes reveal design flaws and often lead to additional patentable improvements. File a provisional patent first, then refine the design before filing the full utility patent.

How do I protect my idea while discussing it with others?

Use Non-Disclosure Agreements (NDAs) before sharing details. However, many companies won't sign NDAs for unsolicited ideas. File a provisional patent first for legal protection before any discussions.

Can I patent an improvement to an existing product?

Yes! Many of my patents are improvements to existing products. The improvement must be novel and non-obvious. Even small innovations can be patentable if they provide clear benefits.

What if someone already invented something similar?

Study their patent carefully. You might be able to patent a different implementation, improvement, or application. Many successful patents are variations of existing concepts applied in new ways.

How do I make money from my inventions?

Several options: (1) License patents to companies for royalties, (2) Start a company to manufacture and sell, (3) Sell patents outright, (4) Use patents defensively if you're in business. Licensing is most common for individual inventors.

The Reality of Professional Inventing

After 100+ patents and 30 years, here's the honest truth about inventing:

Most ideas fail: Maybe 1 in 50 concepts becomes a successful product
Patents aren't guarantees: A patent gives you the right to sue, not automatic money
Persistence matters most: Success comes from consistent effort over years, not lightning strikes of genius
Collaboration is essential: No one invents in isolation—you need engineers, manufacturers, marketers
Learn from everything: Failed products teach more than successful ones
Timing matters: Even great inventions fail if they're too early or too late
User needs trump clever engineering: Solve real problems, not interesting technical challenges

Why I Created InventionPath

After decades of professional inventing, I wanted to share what actually works. Not academic theory, but real techniques I use every day to generate patentable ideas. InventionPath provides the exact tools and methods that have resulted in over 100 patents across power tools, medical devices, consumer products, and industrial equipment.

Whether you're an aspiring inventor, professional engineer, entrepreneur, or just curious about innovation, these proven techniques will help you generate better ideas more consistently.

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