Table of Contents
Background
A mid-sized consumer product division recognized the need to refresh the design of one of its products to highlight new technologies and to stay competitive. The existing design did not fit the latest technology from a customer perception standpoint, and the customer generally perceived the product as outdated compared to newer competitor models. The challenge was to update the styling of the main user interface to highlight modern features while minimizing costs by modifying existing plastic injection mold tooling and minimizing the number of tools to be modified.
Objective
The goal was to revitalize the product with a modern industrial design that would appeal to contemporary consumers without incurring the high costs of developing new manufacturing tools. This project needed to be completed in eight weeks, ready for lagging up a temporary tooling modification on the production tool between production part runs.
Team Composition
The project team included an industrial designer, a styling engineer, a tooling designer, and a project engineer. Their expertise was crucial in balancing aesthetic improvements with practical manufacturing considerations.
Design Phase
The team completed the following tasks in the time frame allotted.
- Market research to identify current trends in products using this technology.
- Meetings with the clients to understand their general expectations.
- Development of several concepts for comparison and collaboration with the client.
- Analysis of the client feedback to determine which design elements were preferred.
- A review of the existing tooling to assess what modifications were feasible.
- Completion of the CAD models for the parts and tooling.
- Creation of the modified assembly process procedure.
Findings
Key insights included a preference for minimalist designs with high-tech features like an updated color display and minimal switches and indicators. The existing tooling was adaptable but required careful modifications to support new design features, especially those related to the interface assembly, mainly where optionality required careful interface management.
Proposed Solutions
The design update involved several strategic changes.
Exterior Redesign
Introduce a sleek, streamlined assembly with a matte finish and minimal visible screws or buttons, enhancing the modern look and feel.
Tooling Adaptation
Modify existing molds to incorporate new design elements, including more ergonomic switches and a redesigned base that could accommodate a color display.
Feature Highlighting
Add subtle labels and graphics around the control panel to emphasize the product’s advanced technology features.
Implementation and Cost Analysis
The tooling engineer developed a detailed plan for modifying existing molds, significantly reducing costs compared to new tool production. The client created prototypes using these modified tool designs to ensure the new design met aesthetic and functional standards and to execute customer focus groups with the latest design.
Conclusion
The styling update met the company’s objectives by delivering a visually appealing and functionally improved product without requiring extensive new tooling investments. The project demonstrated how strategic tooling modifications could effectively rejuvenate an existing product line, increasing market competitiveness and consumer interest.