Our Story

Founded in 2012, Cardboard Helicopter is a boutique industrial design and innovation studio located in Cleveland, Ohio.

We provide a wide variety of Fortune 500 companies, start-ups and entrepreneurs with comprehensive product design assistance from concept to launch. Our small but mighty team of designers and engineers have the creative vision and manufacturing expertise to explore new levels of product design to help you dominate your competition.

We can operate as a complete turnkey solution, or can work at any independent stage of the product development process.

Two men sitting on a couch surrounded by toys and sports equipment, with a wall in the background that reads 'Cardboard Helicopter' and displays a minimalist geometric illustration.
Group of young boys and adult coach posing outdoors for a team photo in front of a brick wall, with a sign indicating they are from Lakewood Boys and Girls Club adult 4th and 5th grades football team, the Scorpions, taken in June 1995.

Our Founders

Having been close friends for over twenty years, we understand what it takes to build enduring relationships. Our shared passions for sports, fun, teamwork, and creativity united us as kids and continue to be the driving force behind Cardboard Helicopter today.

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  • Founder

    Tim Hayes is the co-founder and CEO of Cardboard Helicopter Product Design, bringing over 22 years of product development experience to the helm. A 2007 graduate of the Cleveland Institute of Art, Tim has built a distinguished career characterized by innovation and product design excellence.

    Tim has designed numerous award-winning products, licensed many inventions, and is listed on dozens of patents. His diverse experience spans developing consumer products and medical devices, working for large toy brands and outdoor power tool companies, designing military vehicles, and assisting numerous startups. He has also contributed his expertise at various consultancies.

    The name "Cardboard Helicopter" originates from a story from Tim's childhood, symbolizing creativity and imagination—qualities that he has carried throughout his career. Tim believes heavily in imagination, sustainability, and having fun, principles that are deeply embedded in the company's culture and work ethos.

    At Cardboard Helicopter, Tim leads a talented team of designers and engineers, driving creativity and precision in every project. His dedication to the craft is further demonstrated by his involvement in education, where he actively engages with local schools to promote product design and serves as the vice chair of the IDSA Cleveland chapter.

    In addition to his professional accomplishments, Tim has a rich background in mixed martial arts, including MMA, boxing, Muay Thai kickboxing, and jiu-jitsu. An avid outdoorsman, he enjoys fishing and hunting. Tim also has a minor in drawing and continues to pursue his passion for fine arts.

    Tim Hayes embodies a unique blend of creativity, leadership, and community involvement, making him a driving force in the world of product design.

Black and white portrait of a man with short hair, smiling, wearing a button-up collared shirt, against a plain white background.


  • Design Director

    Carlo Russo is the co-founder of Cardboard Helicopter Product Design, playing a pivotal role in the company's success since its inception alongside business partner Tim Hayes. With a degree in marketing from Kent State University, Carlo specializes in client success and product management, ensuring each project is handled with a personal and meticulous approach.

    Carlo is known for his strong communication skills, facilitating seamless interactions between clients and the design team. His dedication and innovative spirit have led to the development of hundreds of products, with several being listed on numerous patents. One of his most notable creations is the Tricerataco, a dinosaur-shaped taco holder that has gained viral popularity and achieved significant sales.

    Over the years, Carlo has also picked up serious drawing and creative industrial design (ID) skills, enhancing his ability to contribute to the design process directly. Deeply involved in every project, Carlo leads a boutique team committed to excellence and creativity.

    Outside of work, he enjoys hiking, traveling, and camping, drawing inspiration from the great outdoors. Carlo's blend of marketing expertise, product innovation, and client-centric approach makes him an indispensable leader at Cardboard Helicopter, driving the company to new heights in product design.

Two men are sitting at a desk working on drawings or plans, with various papers, markers, and printed images on the desk in a workspace or studio setting.

Our team has over 30 years of combined experience

Two people, a man and a woman, standing in front of a wall covered with illustrations and sketches of various knives and tools, with the man pointing at one of the drawings.
Two people at a wooden table working on sketches of electronic devices, with a potted plant and a pair of white headphones on the table.
A corner display of various children's toys and accessories, including sports balls, a tennis racket, a small bicycle, a scooter, and a toy motorcycle, with shelves and hooks holding toy packaging and accessories.
Office lounge area with a dark gray accent wall featuring white text and a geometric logo that says 'Cardboard Helicopter Product Design'. The space includes a gray sofa, two black chairs, a desk with a computer and office supplies, a backpack on the wall, and pendant lights hanging from the ceiling.

Our Studio is located in an exciting new space in midtown Cleveland, Ohio.

A black stainless steel water bottle with a silver base and lid, featuring the logo and text of Cardboard Helicopter Product Design from Cleveland, Ohio.
Empty conference room with a round table, ten chairs, a window with plants, decorative awards, and modern ceiling lights.
A person sitting at a black arcade-style tabletop gaming machine titled 'Cardboard Helicopter' with a pixelated game screen on top, decorated with yellow leaf patterns and green edges.

We are a team of dreamers, designers, marketers, engineers, thinkers and tinkerers, and we combine creativity and innovation to design exciting products that ensure a successful launch. Each team member brings something highly valuable to the table, consistently providing great value at remarkable new levels of product design.

Our eclectic Cleveland studio fosters creativity and provides us with the necessary tools to help your product and brand take flight.

Modern interior room with forest mural wall, contemporary furniture, and geometric carpet.
Exterior view of a commercial building with the number 2644, featuring a small white lobby with plants, and parking lot with several vehicles under a partly cloudy sky.
Wall filled with technical sketches and concept art of various sports equipment, tools, and gadgets, including skateboards, bikes, scooters, and accessories, in a modern workspace with black chairs and a table with a plant.

Crafting Excellence

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