CAD is powerful, but it can also trick engineers into locking in a design before we even know what problem we are solving. I sit down with Caleb Vainikka, principal designer of Cove Design, to unpack a skill that quietly upgrades every part of product development: sketching. Not as art, not as idle doodling, but as a fast way to think, communicate, and explore manufacturing options you commit to a costly path with CAD.

We dig into what Caleb calls the fuzzy front end of engineering design: those early moments when the difference between sheet metal and injection molding is still up for debate, when assembly trade-offs are unclear, and when cost targets matter more than perfect geometry. He explains how quick 3D sketches, rough prototypes, and rapid iteration help burn down risk and keep a project moving. We also talk about his approach to teaching sketching for engineers, plus the practical resources he shares to help people get started.

From there, the conversation shifts into the business reality of design for manufacturing (DFM): why “just model this bracket” often hides a deeper systems issue, how asking “why” uncovers root causes, and how he prices consulting based on measurable ROI instead of hourly time and materials. We wrap with NDAs and IP ownership, why outside design agencies can accelerate development, and a fascinating look at drone delivery design through the Zipline example.