Technical leadership for health sensing, optics & manufacturing.

KN Consulting helps startups and established companies accelerate product development, testing, and manufacturing readiness for wearable and clinical health sensing technologies — from early feasibility through mass production.

Based in Austin, TX · Available for remote, hybrid, and on-site engagements

Engagement Model

Support across the full product lifecycle, from first feasibility study to full-scale production.

Research

  • Feasibility studies
  • Optics / sensor design
  • Signal processing

Development / NPI

  • Sensor integration / DFM
  • Manufacturing test / calibration

Production

  • Automation / cost-efficiency
  • Root cause analysis / FMEA

Expertise

Deep, hands-on experience across the disciplines that make health sensing products work — and ship at scale.

Biomedical & Consumer Optics

Photoplethysmography, pulse oximetry, spectroscopy, diffuse optical imaging, optical modeling, signal processing, colorimetry.

Manufacturing Test & NPI

Design and automation of robust test & calibration instruments, factory optimization, metrology, FMEA, compliance.

Wearable Health Sensing

R&D for optical, electrical, and thermal wearable health sensors, including ECG sensors and clinical thermometers.

Technical Leadership

Strategy, project management, cross-functional collaboration, mentorship, and public speaking.

Track Record

Over a decade of technical leadership at industry leaders in consumer health technology.

Apple

Instrumentation Design Scientist (Staff-level) · 2017–2024

Led end-to-end test and calibration strategy for Apple Watch health sensing features (Series 4–10), including ECG, blood oxygenation, and cycle tracking. Directed factory test & calibration efforts enabling production of sensors used daily by millions. Escalated optimization proposals that saved $10s of millions annually in high-volume manufacturing.

Fitbit (Google)

Research Scientist · 2015–2017

Initiated and led the project resulting in PurePulse 2.0, Fitbit's next-generation multi-channel PPG sensor technology. Managed the transition of novel health sensors from research prototypes to mass-production hardware.

UC Irvine

PhD, Biomedical Engineering

Developed novel signal processing and hardware systems for high-speed tissue imaging under Prof. Bruce Tromberg (current NIBIB Director), generating 5 peer-reviewed papers and 2 licensed patents.

3 first-author issued patents in wearable and optical health sensing technology, including IP licensed to industry partners.

About Kyle Nadeau, PhD

Kyle founded KN Consulting after more than a decade leading technical strategy for health sensing hardware at Apple and Fitbit (Google). He holds a PhD in Biomedical Engineering from UC Irvine, where his research on high-speed tissue imaging produced five peer-reviewed papers and two licensed patents. He has since been awarded three additional first-author patents in wearable and optical health sensing.

KN Consulting works with startups and established companies to bridge the gap between early-stage R&D and high-volume mass production — bringing the same rigor used to ship health features on Apple Watch and Fitbit devices to your product.

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