Overview
Vuforia Expert Capture is an easy-to-use SaaS AR solution designed to make frontline work more efficient. Vuforia Expert Capture enables companies to capture the knowledge of experts and leverage 3D CAD to easily create, deliver, and scale interactive work instructions and AI-enhanced inspection. Critical quality issues, inconsistencies, or improvement opportunities from the factory or the field can be captured in real-time, then reviewed to enhance products or processes. The design team I worked with helped balance the technical requirements of industrial environments with the need for intuitive user experiences, resulting in a platform that reduces training time by 50% while speeding up the documentation of standard operating procedures by 10X.
Research & Design
Design research · Spatial computing interface design · Mixed reality capture systems · Industrial workflow strategy · Cross-platform design
- Duration: June 2019–January 2020
- Partners: RealWear, Microsoft HoloLens
- Team: Fas Lebbie, Duffy Fallon, Kathy Saviola, James Lema
Confidentiality: The insights and designs shared in this case study are the property of PTC. Specific details have been modified to protect sensitive information.

My Role
I conducted user-centered design research across diverse industrial manufacturing environments, developing strategic workflow optimization.
As a product designer, I helped develop a solution that delivers better user outcomes by reimagining how complex industrial procedures are captured, edited, and consumed through augmented reality interfaces.
Problem Context
The Vuforia Expert Capture product addresses the industrial knowledge gap. The existing process for documenting expert knowledge was inefficient and inconsistent, requiring significant time investments from high-value workers and often resulting in incomplete or difficult-to-follow instructions. Subject matter experts spent an average of 7 hours per week answering repetitive questions that could be addressed through better documentation, creating a substantial productivity drain. The interface needed to accommodate extreme workplace constraints: industrial environments with noise, protective equipment requirements, varying lighting conditions, and workers who prioritized efficiency over technology adoption. Additionally, the solution needed to support diverse user journeys, from experts documenting procedures to reviewers ensuring quality and compliance to novices consuming real-time instructions. Previous interface iterations suffered from excessive complexity, with industrial users abandoning documentation efforts after encountering too many interaction steps.
RealWear AR Solutions
Designed RealWear AR headset experiences within Vuforia, enabling hands-free expert guidance and 50% faster industrial training.
Reduction in Time-to-Productivity
by simplifying capture/playback flows and approvals so new hires learn faster, hands‑free.
Fewer Safety Incidents
through clearer, voice-driven, step-checked instructions that reduced procedural errors.
Savings Per Factory
As Expert Capture replaced legacy SOP training with scalable AR guidance.
Reflections & Impact
The Vuforia Expert Capture solution continues to transform how industrial enterprises preserve and transfer critical knowledge, reducing training bottlenecks while accelerating documentation workflows across 40 manufacturing sites. Beyond operational improvements, the platform addressed the fundamental skills gap crisis facing manufacturing, which is expected to result in 10 million jobs going unfilled. The solution empowered frontline workers with immediate access to expert guidance while freeing senior professionals to focus on strategic initiatives, ultimately reshaping how organizations approach workforce development and operational efficiency in industrial environments. This experience enhanced my technical design background in UI, enabling me to bridge the gap between technological complexity and human expertise to create intuitive interfaces that empower frontline workers while addressing critical business objectives in industrial environments.
Next Steps
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