Product Development | Initial Data and Prototype

Prototype 1

Initially, my role involved reconstructing a CAD model for the foil cutter, with a specific focus on achieving a resolved and smooth A-Side surface. Subsequent revisions were dedicated to refining the geometry of the foil cutter, particularly in terms of the pinch and release mechanism in relation to the body. Additionally, adjustments were made to the handle profile to ensure that the top could be polished without affecting the split line.

DFM. After numerous prototypes, I eventually achieved the optimal balance between functionality and manufacturability. It was crucial to carefully consider tight tolerances for the cutting disks and ensure the snap feature worked seamlessly (how the foil cutter was attached to the main body). Additionally, pull angles and assembly processes always were taken into account to ensure smooth operation during manufacturing.

The iterative process and attention to detail played a significant role in refining the design, resulting in a final product that not only met functional requirements but also optimized manufacturability and assembly efficiency.

Analyzing Data & making changes

“Body” - 2D Study

After solving the Foil Cutter Area, we realized the body geometry worked just for certain types of bottle necks. I started doing an analysis in 3D with different models of bottles geometries, and I found out that the previous design and engineering was done based on one type of bottle. To solve this issue, the body had to grow horizontally.

Throughout the project, numerous prototypes were developed, including prototypes crafted using the actual materials intended for final production. The image showcases a fraction of the prototypes created during the iterative process. It is worth noting that certain components seen in the image were handmade in our workshop to facilitate experimentation and testing, allowing us to evaluate the design's functionality, ergonomics, and overall performance. These physical iterations played a vital role in identifying areas for improvement and validating design decisions, and provided insights that led to subsequent modifications in CAD.

All cork sizes

As a designer, you always want to know how things work...and why they don’t. I got involved in this project in a late phase, initially just trying to solve the “foil cutter” area…then the whole body. Other Engineers were involved in the project before me. Although the project may appear deceptively simple from the outside, it proved to be quite complex. Motivated by a desire to pinpoint the problem, especially considering the base design was rooted in a functioning mechanism, I began a thorough investigation of the original mechanism data provided by the factory. Through this process, I discovered that the issue stemmed from an assembly problem that had persisted since the project's inception. This revelation marked a significant turning point, enabling me to rectify the assembly problem and lay a strong foundation for further enhancements, ensuring the project's success.

Long cork. During testing, we learned about the existence of a long cork of 49mm. Our objective was to achieve effortless bottle opening for any type of bottle and cork size. Building upon the insights gained from our previous 2D analysis, we recognized the need to devise innovative solutions to address this specific challenge.

The complexity of this product arises from various factors, including the abundance of components, the need for precise tolerances, and the utilization of intricate tooling methods. The intricate geometries involved often require specialized tooling actions to account for undercuts. Another significant challenge we encountered was ensuring the stability of the "foil cutter" area. The images below provide a glimpse into the diverse approaches we explored to reinforce the stability and durability of the "foil cutter" area.

Engaging in this project has been a valuable opportunity for personal and professional growth, equipping me with a diverse set of skills that have enriched my design process, collaborating closely with engineers and designers from both OXO and Smart Design, always considering human factors and ergonomics as fundamental aspects of the development process. Recognizing the significance of user experience, we consistently integrated these elements into our decision-making and design choices.