Reinventing Election Usability with a Lightweight, Collapsible Design
Client Need & Project Overview
VotingWorks is a nonprofit startup on a mission to modernize and democratize voting technology through affordable, open-source election systems. For their innovative first product, a precinct-based scanner that reads and records paper ballots, they needed a novel ballot box: one that balanced portability, security, and ease of setup for election volunteers.
They partnered with NOVO to design and engineer this critical component. While a separate vendor developed the ballot scanner, NOVO was responsible for creating the physical ballot box that would receive, store, and protect ballots after scanning.
The ballot box needed to meet or exceed all applicable election security standards along with appearing secure and trustworthy to voters and election workers. It also had to collapse for easy transport and be operable by volunteers, many of whom have limited mobility, without sacrificing durability or ballot capacity. All of this had to be accomplished under strict cost and tooling constraints.
Key Engineering Challenges & Solutions
| Challenge | NOVO’s Solution |
|---|---|
| Meeting election security standards while reinforcing trust | Designed a tamper-evident structure using novel collapsable material for the sides and a rigid frame that complied with election standards and delivered the visual and physical cues voters associate with ballot security. |
| Enabling easy setup and tear down for volunteers with limited abilities | Engineered a lightweight, collapsible structure operable by a single person without bending, kneeling, or tools. Prioritized intuitive mechanisms and minimized latches. |
| Accommodating size constraints for both storage and deployment | Designed for compact storage while ensuring the deployed box could handle a large volume of ballots in varying sizes. Maintained a slim footprint without sacrificing capacity. |
| Ensuring ADA accessibility | Cognizant of all ADA requirements to ensure compliance for those with disabilities including wheelchair users. |
| Preventing user injury during handling and use | Developed soft-close hinges to protect election workers during assembly. Kept overall weight low and simplified the assembly process to reduce strain and risk during transport and setup. |
| Designing for low-cost mass production | Selected the optimal process for parts to reduce tooling costs. Used cost-effective, yet durable fastening methods to maintain security while streamlining assembly and cutting BOM costs. |
Technical Innovations & System Design
Mechanical Design & Material Use
The ballot box broke convention by using a novel approach to architecture with engineered textile sides that articulate with the structure a foldable internal frame, allowing it to collapse into a compact form factor for easy transport and storage. This progressive design was proven effective through prototypes that validate the design’s performance.
Human-Centered Engineering
Understanding that election workers are often older adults, the design emphasized effortless setup, intuitive use, and low physical strain. Volunteers could deploy or stow the box without kneeling, lifting heavy panels, or managing complex latches.
Manufacturing for Scale
This is a niche product that wouldn’t be able to take advantage of the economies of scale present in mass-market items. To meet cost and scalability targets, NOVO made aggressive decisions about materials and assembly:
- Selected manufacturing processes that enabled durable, lightweight paneling with low-cost tooling.
- Developed a classy, professional design while selecting materials that provided for faster, cheaper assembly.
- Every design element was evaluated against BOM cost, tooling feasibility, and manufacturability at medium-scale.
Results & Impact
- The ballot box delivered a rare combination of usability, security, and cost-efficiency:
- Met or exceeded election device standards and ADA accessibility requirements.
- Significantly easier to set up and transport than competing solutions.
- Validated through multiple prototype rounds and user feedback.
- Positioned VotingWorks to compete with legacy providers on both functionality and cost.
Why NOVO?
VotingWorks chose NOVO for more than just engineering support. They needed a partner who could think differently to develop an elegant, refined product with solid craftsmanship on a non-profit’s new product development budget. NOVO brought creative design solutions, fast prototyping cycles, and cross-discipline manufacturing experience that proved critical to success.
This project pushed NOVO to reimagine what a ballot box could be—delivering a product that stood out in both form and function.
Let’s Reimagine What’s Possible
Whether you’re developing a diagnostic device, connected therapeutic, or election technology that breaks with convention, NOVO helps you bring bold ideas to life.
Contact us to discuss your next challenge.
