Standard hair dryers operate at over 85 decibels, a level that can cause hearing damage. User interviews confirmed this was a major pain point, so I worked to translate qualitative feedback into a clear, data-driven goal.
I took ownership of redesigning the two main sources of noise: the fan and the exiting air. My process was grounded in rapid, data-driven iteration.
I designed two key components in Fusion. The first was a custom toroidal fan, inspired by drone technology, to minimize the high-frequency noise from blade tip vortices. The second was the "Fozzle" nozzle, which I prototyped using Mass Loaded Vinyl (MLV) to insulate sound and concentrate airflow.
To find the optimal design, I systematically prototyped and tested over 30 iterations of the fan using a 3D printer. For each iteration, I ran rigorous acoustic tests with a decibel meter, logging the data to track performance against my target. This allowed me to make informed adjustments to the blade count and angle, balancing noise reduction with airflow efficiency.
My final integrated prototype was a success. By combining the toroidal fan and the Fozzle nozzle, I reduced the hair dryer's noise from 88 dB down to 76 dB.
This project was a foundational experience in applying the full human-centered design cycle. It taught me how to ground my engineering decisions in user feedback and reinforced the power of rapid, iterative prototyping to solve complex mechanical challenges.
Tools & Skills: User-Centered Design, Journey Mapping, Rapid Prototyping, CAD (SolidWorks/Fusion 360), 3D Printing, Material Selection (MLV, PLA), Acoustic Testing, Data Analysis.
