The power cord was a once-necessary feature that, now, with innovations in battery technology, charging, and heating element may soon be viewed as an obsolete remnant in the evolution of the appliance.

After witnessing inherent problems with the appliance’s user experience, my immediate instinct was to remove the power cord from the hairdryer and explore battery-powered solutions. I set out sketching and ideating to determine what features could be reconsidered, improved or eliminated. I quickly realized that a folding or collapsible design could provide a dual purpose of further reducing the dryer’s footprint while stored but also create an intuitive orientation for charging on a base.

Looking to start with the most challenging aspect of its larger power requirements and high degree of complexity relative to the other appliances, I began looking for next-gen power sourcing. My immediate instinct was to remove the power cord from the hairdryer and explore battery-powered solutions. After searching for existing cordless product solutions and patents, I was unable to find any viable efforts from the industry.

I then researched the power requirements of the typical hairdryer and cross-referenced those with modern battery capability. I determined the hurdles for innovation had simply been historical battery inadequacies. This insight encouraged me further! Being able to revisit dated product solutions with emerging technology always provokes a fascinating challenge. Bearing in mind that we live in an era marked by rapid technological advancement, I feel compelled to design for the future of that technology.

Due to the advent of the smart device and commercial enthusiasm in the electric car sector, battery science is making staggering advances in both storage capacity and overall battery lifetime. New advancements (though many are not yet commercially available) are redefining our notions of electro-mechanical appliances and opening a new world of cordless technology to the design fields.

According to experts in emerging battery tech, it is becoming possible to charge a battery 50 times faster than previously possible, and to make batteries 30 times smaller. New methods have also emerged to create batteries that are basically infinitely rechargeable. In addition to battery developments, new, powerful, and efficient wireless charging and the standardization thereof, are lowering manufacturing costs and widening the spectrum of cordless appliance possibilities.

Sketching/ Ideating

I hypothesized that an elegantly designed hairdryer, while charging, could be worthy of remaining visible- and even proudly displayed on a surface/ counter top. I began the sketching process as freely as possible with very sci-fi influenced form factors. As I sketched, I refined and streamlined the model while considering individual features and aesthetic cohesion with a charging base.

Model Iterations

Stationary pegs provide the axis upon which the handle hinges. The rear intake side of the hairdryer was intentionally created larger than the front exhaust in order to accommodate airflow restriction around the handle bay inside the main housing and narrowing the airflow chamber for increased output force.

A scratch-free fabric interior protects the hair drier’s polycarbonate surface. The charging base mesh features the similar specifications as the popular Google Home such as hydrophobic and antimicrobial polyester/nylon coating. Overlapping ‘lips’ and annular snap fits were added to the rear mesh and main housing to insure a tight but impermanent fit for prototyping

With the careful planning during component research and CAD modeling, I endeavored to materialize a prototype to gauge the accuracy and compatibility of a first round of components including the handle interface buttons and the axis upon which the handle/main housing rotate and if the wiring would successfully cross between the two without impeding the folding function. I exported the solid models of individual components from Rhino with adjusted mechanical tolerances in hopes of getting tight assembly and a satisfying ‘snapping’ together of components.

I sliced the files in Cura 3D Slicer and printed them from my home Ender 3’ 3D printer. With many failures, revisions, and re-calibrations of the printer and model geometry, i was able to achieve a model of outstanding fidelity. Delicate sanding, painting, and hand finishing created a crisp showroom-quality prototype.