14 Weeks ( 2025 Fall )

Duration

Adobe Photoshop, Adobe Illustrator, Solidworks , Keyshot Studio

Software

Rapid Prototyping, Sketching, 3D Modeling, 3D Printing, Research

Skillset

Design a half-face respirator for factory operators that combines effective protection with comfort, adaptability, and clear communication in demanding work environments

Dyson is an engineering-driven brand that blends advanced technology with clean, minimal design. Its products emphasize precision, performance, and intuitive interaction, often expressed through refined forms, material contrast, and subtle color accents, transforming everyday appliances into elevated and forward-thinking experiences.

Persona

Gender : Male

Name : Jackson Miller

Age : 33

Location : Houston, Texas

Profession : Senior Fabrication Technician

Annual Income : $60,000 ~ $75,000

Residence : Lives in a small house near the industrial outskirts.

Workplace: Metal and composite parts factory — cutting, sanding, grinding, and coating areas

Activities & Habits : Cuts metal sheets, sands composite surfaces, and apply protective coatings before inspecting the finished parts. Always wears respirator when cutting or spraying, switches filters regularly.

Pain Point

Pressure & Discomfort

Fogging of Glasses & Goggles

High Breathing Resistance

Poor Facial Fit

Communication Barriers

Usage Scenario

Human Factor Study

These study highlights how intuitive interaction, grip comfort, and clear visual cues shape the overall user experience. Small details such as pressure distribution, strap adjustment, and assembly steps have a significant impact on usability. Understanding these factors helps guide design decisions toward a more comfortable, efficient, and user-friendly product.

Insipiration

Concept Development through Sketches

Form Exploration

Connection Mechanism

Final Concept

These sketches explore the early form development of the Dyson Airguard respirator. Through quick iterations, I tested different proportions, filter placements, and head support structures to refine both ergonomics and airflow while maintaining Dyson’s design language.

These sketches explore the connection mechanism between the respirator and the head support system. Different attachment and adjustment solutions were studied to ensure stability, comfort, and ease of use while maintaining a clean and integrated form.

The final concept of the Dyson Airguard respirator integrates a modular filtration system with a supportive head structure to improve comfort, airflow, and stability. The design balances functional performance with a clean, recognizable Dyson aesthetic.

Final Phase – Surface & Detail Refinement

3D Modeling Phases

This phase focuses on building the base geometry of the Airguard respirator in 3D. The model establishes the overall proportions of the product while developing the connection mechanism between the respirator body and the head support structure.

Phase 1 – Early Form & Mechanism Modeling

Phase 2 – Form & Structural Refinement

This phase focuses on refining both the form and structural components of the Airguard respirator. The head support system, strap integration, and connection mechanism were further developed to improve ergonomics, stability, and overall visual balance.

This phase focuses on refining the final surfaces and details of the Airguard respirator. The overall form, proportions, and connection mechanisms were finalized, with a snap-in mechanism developed for secure and intuitive attachment.

Mock - Up Studies

These mock-ups were developed through quick 3D printing to explore form, fit, and how the parts come together. Through hands-on iteration, they helped refine proportions, improve comfort, and better understand the relationship between components before moving into more refined stages.

CMF Board

Othographic Drawing

Internal Volumetric Study

Head Cradle

Battery

Neck Strap Buckle