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Why the Simplest Products Are the Hardest to Design, Inside BrainBlink’s Engineering

Why the Simplest Products Are the Hardest to Design, Inside BrainBlink's Engineering
Photo Courtesy: BrainBlink's Engineering

By: Ethan Rogers

BrainBlink looks simple: a pocket-sized piece with buttons. The effortless experience is exactly what the design team wanted you to feel. BrainBlink is an arcade device supporting eight games that you can pick up, play with and put down at any moment.

And the problem is that effortless products are almost never simple to build.

“The products that feel the simplest are often the hardest to design well,” says Josh Fairbairn, founder of Morpho, the manufacturing company behind BrainBlink. “You look at it and think ‘it’s just a game.’ And then you realize the iteration behind that simplicity was enormous.”

BrainBlink launched on Kickstarter in 2025 and hit 100 percent funding in under eight hours. The campaign finished at over 1,500 percent of its goal. The numbers are impressive. But the real story is what it took to get there.

Backers From 20+ Countries

The campaign attracted backers from more than 20 countries. That scale of interest reflects something deeper than just product curiosity. It reflects a hunger for something that actually works, a device designed by people who understand both the problem and the manufacturing reality required to solve it.

BrainBlink is a collaboration between Morpho and LastObject. Morpho has shipped more than 2,000 products over 14 years. They know what it takes to get a product from an idea to a factory to a doorstep. LastObject built the world’s first reusable cotton swab. It sold in millions of units across dozens of countries and won a Red Dot Design Award in 2024. They know how to make something people actually use every day.

That combination of proven manufacturing expertise and proven product design is why backers from 20+ countries trusted BrainBlink before it was even built.

The Engineering Behind Simplicity

The engineering behind BrainBlink’s simplicity started with a single principle: every component had to serve the experience. Nothing decorative. Nothing that looked good in a render but created problems on the assembly line.

The tactile feedback. The button response. The way the screen illuminates. Each of these required iteration. Not because they were difficult in isolation, but because they had to work together at scale, across thousands of units, without variation.

Morpho’s approach to manufacturing begins long before production starts. Each project receives a comprehensive quality standard document that establishes tolerances, inspection methods, and defect categories before tooling begins. For BrainBlink, that meant defining exactly how the buttons should feel, how much resistance they should have, and what constituted an acceptable variance.

Critical components are sourced directly from qualified suppliers. These relationships are built over years, which means Morpho knows the quality of work, the reliability of timelines, and the pricing structure before a project starts. Components are individually inspected before they reach the assembly line.

The company places particular emphasis on Design for Manufacturability, or DFM. This is the discipline that identifies production problems before they become expensive ones. For BrainBlink, DFM happened before tooling was committed. Once a mold is cut, design changes become structural and expensive to revisit.

The AI Makes Sure It Stays Hard

Most games have a fixed difficulty. Once you learn the pattern, you stop improving. BrainBlink’s AI watches how you perform on every run: your speed, your error rate, where you hesitate, and recalibrates before the next one.

Players who have been using it for six months are playing at a level that would be impossible for a beginner to follow. That is the point. It should always feel like the edge of what you can do.

The AI is one of the reasons the product works so well and why backers from 20+ countries trusted it enough to fund it at 1,500 percent of goal. It is why people keep playing.

Iteration Until Success

The iteration behind BrainBlink was not visible in the final product and that was the point.

The team tested different button materials. They tested different screen technologies. They tested different ways to house the battery. Each test revealed constraints that the previous iteration had not accounted for. Each constraint led to a new design decision.

“That’s true of almost every product we’ve built,” Fairbairn says. “The effortless ones are the most work.”

That consistency did not happen by accident. It happened because someone spent months thinking about what could go wrong, and then built systems to prevent it from happening.

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