Project Overview
This project applied Design for Assembly (DFA) principles and SolidWorks modeling to reverse engineer and optimize a Dyson bladeless fan design. The project focused on understanding its innovative design, streamlining assembly, and improving manufacturability through targeted material and process selection. The detailed teardown revealed a unique airflow system and provided a foundation for design optimization and cost reduction analysis.
The Challenge
The primary challenge was to reverse engineer a complex consumer product to understand its design principles and then optimize it for improved manufacturability. The Dyson fan initially consisted of 48 total parts (38 unique), presenting a significant opportunity for design simplification. The goal was to reduce the part count and improve assembly efficiency while maintaining the product's core functionality, signature bladeless design, and aesthetic appeal.
Our Solution
A detailed reverse engineering process was conducted, beginning with a complete teardown and measurement of all components, which were then modeled in SolidWorks. A comprehensive DFA analysis was performed to identify inefficiencies and guide part reduction strategies. Four fundamental design changes were proposed: eliminating three wire holders, removing one of the three swivel base supports, removing the sensor hatch by attaching the sensor directly to the base, and integrating the LCD/PCB holder into the swivel base plate. Ashby charts and decision matrices were used to validate the existing material selections—primarily PC/ABS, POM, and stainless steel—ensuring an optimal balance of strength, cost, and manufacturability. Manufacturing processes like injection molding, forging, and wire drawing were analyzed and confirmed as the most efficient methods for high-volume production.
Dyson Gallery
Design Changes
Interactive Model
Exploded assembly view showing component relationships
Key Results
Technologies & Tools
Project Timeline
Disassembly & CAD Modeling
Complete teardown of the Dyson fan, followed by measurement and detailed modeling of all components in SolidWorks
- Complete initial CAD model
- Technical drawings
- Preliminary Bill of Materials
DFA, Material & Economic Analysis
Conducted in-depth analyses to identify optimization opportunities including DFA, material choices using Ashby charts, and economic analysis
- Initial DFA analysis report
- Material selection matrices using Ashby charts
- Complete economic and break-even analysis
Redesign & Finalization
Based on the analysis, design changes were implemented to reduce part count and simplify assembly
- Redesigned CAD model
- New DFA analysis showing 13.9% score improvement
- Updated economic report reflecting cost savings
Technical Specifications
Key Features
Team
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