The Zuli Smartplug is a feature-rich home automation product, which combines energy monitoring, lighting and device control and dimming, and user presence detection. After developing a functional electrical prototype, Zuli asked Cooper Perkins to develop a fully-integrated mechanical and electrical design that was suited for high-volume production, and adhered to UL and FCC regulatory requirements. Challenges included heat dissipation (tricky, considering use of triac dimming up to 300W and switching up to 1,000W), reducing RF interference, radio tuning, and high-quality cosmetic requirements. Addressing problems and implementing solutions required a combination of constant vigilance of effects on the Smartplug form-factor and cosmetics, with a willingness and flexibility to address fundamental problems when required.