Engineering Health | Air Purifier Design & Manufacturing Strategy

This project focused on developing a consumer-grade air purifier for a company with a strong background in industrial custom air purification systems. While the client had deep expertise in purification technology and had already achieved benchmark efficiency through a functional sheet-metal prototype, they were now looking to enter the consumer market where design, usability, and cost play a critical role alongside performance.

We were engaged for industrial design, prototyping, and production planning. Starting from concept development, we created multiple design directions aligned with the brand theme, aesthetics, CMF, ergonomic principles, functional requirements, and cost-effective manufacturing. The enclosure architecture, airflow pathways, filter integration, and user interaction were carefully designed to balance performance with manufacturability and consumer appeal.

Prototypes were 3D printed to validate form, fit, and function, followed by a detailed production planning assessment covering both sheet metal fabrication and injection molding. Based on current market size, investment considerations, and fabrication costs, the client chose to begin production using aluminium sheet metal, with the design optimized for a future transition to injection molding as volumes scale.

Impact

3-month execution timeline covering 4 design iterations and 2 functional prototypes

Fabrication cost reduced to one-third compared to injection molding when tooling investment was considered

Optimized waste management through early manufacturing planning

Improved fund utilization and inventory control, reducing financial and stock-related risks during market entry