I design AI and data-heavy systems for regulated industries

I'm Matthew Zillhardt, the designer companies call when the workflow is too complex, the compliance requirements are too strict, and the cost of a bad decision is too high. Senior Product Designer who's shipped AI and data-heavy systems for the Social Security Administration, Optum, and DuPont — where a bad interface creates legal exposure, delays benefits, or misses key opportunities

Who I Work With: I partner with federal agencies, healthcare payers, and enterprise software companies building AI and data-heavy products for regulated industries.

Core Differentiators

Currently open to Senior/Staff Product Design roles in federal, healthcare, AI, or enterprise software.

Interested in working together? Email me or connect on LinkedIn.

case studies

Optum - RHRP document processor

How I cut analyst decision time by 33% on a federal document-processing AI platform

I designed dashboards and data visualizations that cut analyst decision time by 33% on a federal document-processing AI platform — so policy researchers could act on data instead of hunting for it.

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a preview image of the Optum RHRP application. It shows the browser application on a monitor

Optum - Project Ana

Turning raw federal data into faster decisions: a 0→1 AI platform for policy researchers and data scientists

I led 0→1 design on an AI platform for federal policy researchers and data scientists — turning raw federal data into faster decisions by integrating safety guardrails and WCAG accessibility.

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Sky Solutions - SkyAI Application

Designing a federal AI assistant from 0→1 with safety guardrails and Section 508 compliance

I designed a federal AI assistant from 0→1 with safety guardrails and Section 508 compliance — giving Sky Solutions a modular, market-ready product they could pitch to government clients.

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a preview image of the SkyAI application. It shows the browser application on a monitor

Subaru of America - warranty claim system

Redesigning warranty claims to cut processing time by 27% for dealership warranty administrators

Subaru of America (SoA) had an aging warranty system that their dealerships were utilizing. They needed an updated system built off of Angular and wanted to address certain usability concerns and make the system more seamless for the end user technicians.

Same problem, different domain: enterprise workflow software where a slow interface directly impacts customer experience and operational cost.

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DuPont - MCI Semiconductor Insights

Helping semiconductor analysts spot production issues 33% faster through data visualization

The DuPont MCI Semiconductor Insights web application was created due to the difficulty that their semiconductor group had with gathering data needed to make integral business decisions. This application scraped data from the web and allowed users to manually upload data, at which point the system would generate data visualizations in the dashboard system for the end users. This allowed the analysts to make more informed choices more quickly.

Same problem, different domain: enterprise analytics where analysts need to spot issues and opportunities before costly delays pile up.

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about

Who am I?

I partner with federal agencies, healthcare payers, and enterprise software companies building AI and data-heavy products for regulated industries — where a bad interface creates legal exposure, delays benefits, or misses key opportunities.

My path to UX wasn’t linear—it began with a love for art and making things people enjoy. I studied fine art and digital media, experimenting with sculpture, animation, and even basic game design, before transitioning into graphic design and print after college. By chance, I joined a digital agency where I learned HTML/CSS, designed emails and webpages, and discovered the power of analytics, A/B testing, and user feedback—long before I even heard the term ‘UX.’ Over the years, I self-taught UX principles through research, collaboration, and trial-and-error across industries like finance, insurance, and government, blending my foundation in layout, color theory, and typography into crafting better experiences.

That non-linear path is why I'm good at ambiguous, high-stakes problems: I've never had the luxury of a clean brief.

Based in Allentown, PA, I geek out over design systems, team workflows, and—outside of work—LARP, board games, plants, and my cats.

My tools are Figma, Miro, Axure RP, Adobe CC, Adobe XD, and pen and paper to sketch out ideas.

process

7 key questions I always ask before I start designing anything:

1. Why are we doing this?

What's the business outcome — and what's the cost of getting it wrong? In regulated domains, "because leadership wants it" isn't enough. I need to know whether this reduces legal exposure, speeds up a decision, or prevents a costly error.

2. Who are we doing this for?

Not just "the user" — the specific person under pressure. A federal policy researcher racing a deadline. A dealership warranty admin processing claims between customer calls. A data scientist who needs to trust the AI before acting on it. Designing for "users" is easy; designing for someone whose job is on the line is different.

3. What evidence do we have?

In high-stakes domains, assumptions are expensive. I ask: What do we know from research? What do we know from support tickets, error logs, or compliance audits? What are we guessing — and how will we test it before it ships?

4. How do we measure success?

Business metrics and user metrics, tied together. Reduced decision time. Fewer support calls. Lower error rates. Faster claims processing. If we can't name the number we're moving, we're not ready to design.

5. Are there any significant risks?

This is where regulated domains differ from consumer software. What's the legal exposure if this workflow fails? What happens if the AI is wrong — and who catches it? How does this hold up under Section 508 audit? A bad interface here doesn't just frustrate users; it delays benefits, creates liability, or lets vulnerabilities spread.

6. Are there technical restrictions?

Legacy systems, compliance requirements, data residency, accessibility standards, AI model limitations. At SSA, I designed within the US Web Design System and Section 508. At Optum, I designed around AI guardrails and HITL workflows. Constraints aren't obstacles — they're the design space.

7. Who needs to be involved?

In regulated domains, it's never just product and engineering. Legal, compliance, accessibility, subject-matter experts, federal stakeholders. I've run design workshops in Figma, FigJam, and Miro to align engineers, PMs, and stakeholders on high-stakes projects — and I've learned that the earlier you bring in the people who can say "no," the faster you get to "yes."

how I work

Trade offs

  • Subaru of America: chose speed over polish → the team needed a working prototype for a trade show. I prioritized a clear, demo-ready flow over edge-case coverage and visual refinement — a reminder that "done enough to learn from" often beats "perfect but late.

Ambiguity

  • Optum's Project Ana: no research, no documentation → created assumptions, tested, iterated.
  • SkyAI: unclear goals → aligned on "success" before designing anything. Federal and healthcare projects rarely come with clean briefs — I've learned to create assumptions, test them fast, and iterate before the cost of being wrong compounds.

Systems thinking

  • Optum's Project Ana: aligned metrics + edge cases across flows so the experience stayed consistent at scale. In AI and data-heavy systems, edge cases aren't edge cases — they're the main event. I design for the exception, not just the happy path.

How I've changed

  • DuPont → Optum's Project Ana: I stopped thinking in terms of the "perfect" step design process and started thinking on business alignment. In enterprise software, the "perfect" design process is the one that ships on time and meets business metrics.
  • Most importantly, I've learned to cut out inefficiencies, know where and when to cut processes short, and deliver on company demands.