DriAir Summer 2016
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Contents Meet the Team_4 Project Brief_6 Opportunities_7 Ghant Chart_8 Research_10 Target Market_26 Persona_28 Ideation_32 Final Solution_36 Manufacturing Details_40 Glossary_44
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Meet The Team
Hannah Cover
Archana Srinivasan
Vitaly Pankoff
Meghan Preiss
Industrial Design BFA
Industrial Design BFA
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Idustrial Design MFA
Industrial Design BFA Service Design BFA
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Project Brief The goal of the project is to design a hair dryer containing internal features commonly used in the design of injection molded parts such as ribs, bosses and snap fits while following standard rules and guidelines for plastic part breakup, parting line location and wall thickness.
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Opportunities How to improve the hair drying experience for every girl on the go?
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Week One
Market Research Manufacturing Research Ideation Prototyping CAD Modeling Rendering Rapid Prototyping Processbook
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Week Two
Week Three
Gantt Chart Week Four
Week Five
Week Six
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Research The team completed the project through the double diamond process. They started out researching a broad variety of hair dryers and accessories for hair; flat irons, curling wands, and brushes. They conducted surveys for a vast audience and studied the design intents of many products. Through this research the team narrowed down to the main opportunities to focus their design on. They then moved into researching a broad variation of materials, and manufacturing processes to create a innovative and more sustainable product.
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The team created a short survey for a variety of people to complete. The survey collected information on the functions people used their hairdryers and how long on average do people use the product. This survey gave them the insights to which they used within our designs.
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Insights • Overdone gun design • Not compact enough (Size and shape) The gun shape prevented this product from becoming as compact as possible unless contained in a box or the handle was folded. • Gun design is not convenient. The gun shape created a distance the hand and hair which in turn lost ease that one gets from running their hand through hair. • No battery operated ones or ones with longer lasting charge The ever present cord is seen as a hassle to manage when drying hair as it is yet another thing to worry about.
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Materials The team looked into the pros and cons of many materials. They wanted to push the boundaries and find the limits of materials they researched the typical hair dryer materials, extreme materials that would fail with the heat, and materials that would work well but are very expensive. The team wanted to create a bank of knowledge to find new valleys for innovation.
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Thermoplastic Silicone Vulcanizate (TPSiV) Si-Rubber is mixed with TPU. Si-Rubber gives a silky feel, it is heat resistant, chemical resistant. Combined with TPU provides an eco reaction and no emission. TPU provides flexibility, anti abrasion, it is good to process and has good bonding properties. TPU has a great colorability. TPSiV comes in pellet form and can be injection molded or multi injection molded TPSiV is usually found on smartphone cases, seals for waterproofing, earphones, grips, and soft touch overmolding applications.
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Acrlonitrile Butadiene Styrene (ABS) ABS is low cost and versitile. It is easy to process and extremely tougth with good impact resistance. ABS is also recyclable. It allows for high tolerance and it scratch resistant. It is easy to color and has good dimensional stability. It is flammable and has poor resistance to UV light. ABS comes in pellet form and can be injection molded, extrusion, blow moulded and structural foam. It does no warp or shrink during manufacturing. ABS is usually found on legos, shower trays, food processors. It can be added to other materials to make a stronger plastic.
Polyamide (PA) PA is widely availble and resistant to high temperatures. It has high tensile strenght and low friction. It is also recyclable. Polyamide has poor moisture resistance and limited chemical resistance.
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PA is difficult to extrude but is better suited for injection molding. It can be strung into fibers for multilayer films. It has the ability to be filled with other materials such as glass fibers to enhance it. PA is ususally the replacement for metal in structural parts of furniture and sports equipment. It is found within carpets, musical instrument strings, seat belts, and more. A derivative of PA is nylon which is used in textiles and shoes. It is also used in food packaging due to its great temperature resistance.
Polybutylene Terephalate (PBT)
PBT has a shorter production cycle compared to most plastics due to its lower mold temperatures. It can be injection molded, extruded, blow molded, and can be used as surrounding material. It takes surface finishes well.
PBT is strong and hardwearing. It has short production times and is widely available. It has great wear resistance and long term use at high temperatures. PBT is also recycable.
PBT is normally used on exterior car trim like windshield wiper covers, handles, and mirror housings. It is used in oven handles and iron handles.
PBT is semi-expensive.
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Ionomer Resins Ionomer Resins are extremely tough and resilient and have good chemical resistance. They are versatile, widely available and recyclable. Ionomer Resins have high clarity and high melt strength. Ionomer Resins are not the best sustainable option due to the petroleum base. It can be injection molded, extruded, foamed, thermoformed, or used a powder coating. It can also be a resin modifier to give more strength. Ionomer Resins are used in abusive environments, toold handles, bowling pins, dog toys, etc.
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Melamine Formaldehyde (Melamine) Melamine has good resistance to chemicals, impact, and heat. It is non-toxic, has an great surface finish, and takes color well. It is semi-expensive and it is not recyclable. Melamine comes as a compound or a resin. It can be injection molded, compression molded, and extruded. It can be molded with variable wall thicknesses. Melamine is typically used in ashtrays and cooking handles. It is used in dinnerware and plastic laminents along with coat buttons.
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Silicone Silicone is extremely versatile. It has a wide variety of production techniques and is widely available. It is also extremely resistant to heat and chemicals. It is semi-expensive, can be difficult to mold and is not recyclable. Silicone can be injection molded, extruded, calendared, blow molded, rotational molded, and printed as ink. Silicone is used in many applications. It is sealant in packaging and bathrooms, it is used in cooking dishes and as handles to many products.
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Components The team researched the components that make up a typical hairdryer along with the components that could be a more sustainable and better replacement.. They want to create an innovative design and that means working from the inside out.
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External battery Advantage: Easy to dismantle, Less charging time, Disadvantage: Bulky, changes overall shape of product
Thermacell Advantages: it is a good source of heat Disadvantages: does not conduct electricity.
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Induction Charging Advantages: An internal battery is usually integrated into the device and doesn’t affect its shape in a major way. Disadvantages: Lower efficiency, Devices take longer to charge, More expensive.
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Target Market The target market is the time constrained female. She is in her mid twenties and is always traveling to work and around the world.
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Grace Lee Location: New York City, NY Age: 27 Education: Fashion Marketing MFA Salary: 70k
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I need to be prepared for anything to happen. My everyday tote bag carries all my necessities.
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Zara
Phillip Lim
Burgers
Sushi
Suburbia
City
Starbucks
Artisnal
Organized Happy Healthy Prepared Outgoing Professional
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Design Criteria Combining the problems our team discovered during the research phase and the intended target market, the team arrived at the following design criteria.
Minimal This design must have minimal buttons and features.
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Portable This design must be lightweight and small in size.
Induction charging This design must be chordles to maximize mobility
High Quality This design must be high quality and low maintainence.
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Sketches
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Finalized Sketches
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Sketch Models
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DriAir This product is a synthesis of the research, market surveys and design aesthetics. Every curve was designed with a foresight and precision so as to retain the design intent. Minimal: simple and pure shape that is easily held by hand Portable: Lightweight and portable Induction charging: Cordless and less of a hassle High quality: Long lasting and low maintenance. Durable materials
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DESCRIPTION
QTY MANU.PROCESSES
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CHROME PLATED FRONT LIP
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INJECTION MOLDED FOLLOWED BY VACUUM METALIZATION
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PRE PERFORATED STEEL MESH
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OUTSOURCED
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NICHROME COIL
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OUTSOURCED
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MICA HOLDER
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LASERCUT
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ABS EXTERIOR TEXTURED SHELL
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INJECTION MOLDED WITH IMC
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LITHIUM ION RECHARGEABLE BATTERY
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OUTSOURCED
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ABS SWITCH PLATE CLASS-A
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INJECTION MOLDED WITH IMC
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SWITCH
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INJECTION MOLDED
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MICA FUNNEL
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LASERCUT
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MOTOR
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OUTSOURCED
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PRE PERFORATED STEEL MESH
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OUTSOURCED
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ABS AIR INTAKE PLATE
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INJECTION MOLDED WITH IMC
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MICA FRONT PLATE
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LASERCUT
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Glossary: Manufacturing Processes The team researched the possibly avenues of manufacturing and the processes that made sense within the design limitations they were given. The team did research through a series of lectures, videos, and reading to give them an overview and deeper understanding on how to create the best design to be manufactured and machined.
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Injection Molding
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Injection Molding s a manufacturing process for producing parts by injecting material into a mold. It is a widely used and well-developed process that is great for rapid production of identical parts with tight tolerances. There are 3 parts to this process: injection, mold, and clamping. Granular plastic is fed by a forced ram from a hopper into a heated barrel. As the granules are slowly moved forward by a screw-type plunger, the plastic is forced into a heated chamber, where it is melted. As the plunger advances, the melted plastic is forced through a nozzle that rests against the mould, allowing it to enter the mould cavity through a gate and runner system. The mold remains cold so the plastic solidifies almost as soon as the mould is filled.
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Vacuum Metalized Plastic
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Cavuum Metalized Plastic Is a decorative process of plating a plastic component with a metal. First, the plastic component is washed and coated with a base coat, so that the metal layer is smooth and uniform. Next, a metal is evaporated in a vacuum chamber. The vapor then condenses onto the surface of the substrate, leaving a thin layer of metal coating. The entire process takes place within a vacuum chamber to prevent oxidation. Depending on the component’s application, a top coat may be applied after deposition to increase properties such as abrasion resistance. Metalized plastic components that receive their coats via this process are found in a range of applications, from automotive interior parts to certain types of foils.
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In Mold Coatings (IMC) IMC is a process done within the mold to color and create textures on a plastic component. A thin film of specially formulated paint / gel is sprayed directly into the open mold prior to injection or compression molding. This shorten production cycles, reduce manufacturing cost and impact on the environment, and placing their composite products on a more cost-competitive footing.
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Pad Printing Pad pringint is a printing process that can transfer a 2-D image onto a 3-D object. This is accomplished using a silicone pad that can pick up an image from a flat plane and transfer it to a variety of surface (i.e. flat, cylindrical, spherical, compound angles, textures, concave surfaces, convex surfaces).
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