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Kool Jack Cooling Dog Vest: Product Development

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Kool Jack Cooling Dog Vest: Product Development
Konstantin Dolgan

Written by Konstantin Dolgan, Ph.D., NPDP

Founder & CEO, Product Development Engineer

Published August 10, 2026

Loran and Linda Ebarb of New Orleans knew evaporative dog vests fail in humid Louisiana heat. We designed the Kool Jack vest around ice-pack cooling combined with evaporation, prototyped it in fabric, and manufactured the first batch through our short-run production — then built their website and promo video. The Ebarbs went on to mass production.

Project at a glance

Client
Loran and Linda Ebarb, New Orleans, Louisiana
Industry
Pet products
Starting point
Evaporative cooling vests that do not work in Louisiana humidity
What we delivered
Market research, concept design and 3D CAD, fabric prototypes, DFM, short-run production, website, photo and video
Design decision
Combined ice-pack and evaporative cooling so the vest works in humid and arid climates
Outcome
First batch produced through our short-run capability; the client moved to mass production
The promotional video we produced for the Kool Jack once the vest was in production.
Video page ↗

The client

Loran and Linda Ebarb are a dog-loving couple from New Orleans, Louisiana. They watched their own dog tire quickly in the heat — dogs do not sweat — and found that the cooling vests on the market did not help where they live.

Those vests rely on evaporative cooling, which barely works in saturated Louisiana air. The Ebarbs brought us a straightforward idea: build ice packs into the vest so cooling does not depend on the weather. They came to LA NPDT for the whole path — product development services under one roof.

The challenge

The clients arrived with four connected problems rather than one:

  • Design a cooling vest that works in humidity — concept design and 3D CAD, with ice-pack pockets that sit where a dog actually needs cooling and do not chafe or shift when the dog moves.
  • Build a demonstration prototype the founders could put on real dogs and show to buyers and investors.
  • Prepare the design for manufacturing, including the fabric, pack sizing and stitching a factory could repeat at volume.
  • Create a website and video that explain the features clearly to pet owners who have already been disappointed by evaporative vests.
Ice pack pockets sewn into the Kool Jack vest shown open on a work surface

Our solution

We began where every project does, in the discovery stage: mapping the pet product market, the competing vests and their reviews. Negative reviews were the most useful input — they said plainly which climates the incumbents failed in.

That research changed the concept. Instead of replacing evaporation with ice packs, we combined both, so one vest serves humid and arid markets. The dual-mode decision widened the addressable market without adding a second product.

Our fabric prototyping capability kept iteration fast. Each prototype went onto a dog, and fit, pack placement and strap tension were corrected before the design was frozen. Our prototyping services exist so decisions get made on real samples rather than on renderings.

With the design settled, our short-run production ran the first batch of vests — enough to sell, photograph and show without committing to mass-production quantities.

The Ebarbs returned for the launch package. Designers, developers, photographers and videographers agreed on what makes the vest different, we cast dogs for the shoot, and our copywriters wrote the storyboard and site content while filming was scheduled.

The result

The clients got more than a demonstration prototype: a market-viable pet product optimized for user experience, cooling performance and mass production.

Using the production samples and the marketing materials, Loran and Linda raised the funding for manufacturing and marketing, then moved from our short-run batch into mass production.

The website and videos carry the message: they show the vest in use, explain the dual cooling modes, and raise awareness of a real welfare issue for dogs in hot, humid states.

Dog wearing the Kool Jack cooling vest during an outdoor photo shoot
Side view of the Kool Jack vest showing adjustable straps around the dog's chest
The Kool Jack on real dogs — fit and strap tension were corrected on live samples, not on renderings.
Top view of the Kool Jack vest laid flat showing the ice pack pocket layout
Close-up of the Kool Jack vest fabric and stitching prepared for manufacturing
Construction detail: ice-pack pockets combined with evaporative fabric.
Kool Jack vest production sample in blue photographed on a plain background
Dog resting comfortably while wearing the Kool Jack cooling vest
Production samples used for the launch photography and investor meetings.
Large breed dog wearing the Kool Jack cooling vest on a walk
Smaller dog wearing a size-adjusted Kool Jack cooling vest
Sizing across breeds: the vest had to work on very different body shapes.
Kool Jack branding and packaging photography produced for the product launch

Capabilities used on this project

  • Rapid prototyping services

    3D printing, CNC machining, urethane casting and functional prototype builds with published materials, tolerances and lead times.

  • Low-volume manufacturing

    Bridge tooling, short-run production and supplier management for first commercial batches.

How the Kool Jack vest beat humidity with two cooling methods

  1. Market research into a real product gap

    Discovery-stage analysis of the pet product market showed competing vests rely on evaporative cooling — ineffective in humid weather, since dogs don't sweat. Competitor reviews, positive and negative, told us exactly where the product-market fit opportunity was.

  2. Dual-mode cooling design

    We designed the Kool Jack to combine ice-pack cooling with evaporation, capturing both humid and arid markets. Our fabric prototyping capability made iteration fast — each prototype gave the clients hands-on review and fed design optimizations before manufacturing.

  3. Short-run manufacturing to mass production

    Through our short-run production capabilities we manufactured the first batch of vests, after which the Ebarbs moved into mass production. They returned for the website and video marketing to launch the product.

Cooling vest technologies compared
MethodHow it worksHumid climatesArid climates
Evaporative onlyWater evaporation from fabricFails — saturated airWorks well
Ice-pack onlyPhase-change cooling packsWorksWorks, shorter duration
Dual-mode (Kool Jack)Ice packs + evaporative fabricWorksWorks — widest market

Questions about this project

Straight answers from the engineers who ran the build. Have a different question? Ask us directly.

Talk to an engineer
Why don't standard cooling vests work in humid weather?

They rely on evaporation, and humid air is already saturated — the water can't evaporate, so the vest can't cool. That is exactly the gap the Kool Jack's ice-pack design was built to close.

How do you prototype a fabric pet product?

In fabric, iteratively. Our fabric prototyping capability let us produce real vests the Ebarbs could put on dogs, review hands-on, and feed back into design optimizations before committing to manufacturing.

Can you manufacture a first batch before mass production?

Yes — we produced the Kool Jack's first batch through our short-run manufacturing, letting the founders validate the market before scaling to mass production.

Do you also handle pet product marketing?

For the Ebarbs, yes: after design and manufacturing we built the Kool Jack website and promotional video, highlighting what makes the vest unique.

How is a dog vest prepared for manufacturing?

By freezing the things a factory has to repeat: fabric and pack specification, pocket placement and stitching, strap hardware and the size grading across breeds. We settled those on real samples worn by real dogs before the Kool Jack went to a first production batch.

Industries this project belongs to

See how we approach development in each of these categories, and the other products we have taken from sketch to production there.

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