FFP3 Mask BLS Zer033 Flat Series
Product Design and manufacture of the disposable three-flap filtering facepiece for industrial use, for protection against dust and odors.
0. NDF Impact
1. PRODUCT DEVELOPMENT BRIEF
Customer BLS Group decides it wants to replace two of its products with a new, higher-performance disposable mask by adopting a new production technology. The new product is to be designed and manufactured from scratch based on the new production line, identifying differentiating selling points from competitors.
2. DESIGN CHALLENGES
Project challenges are located on various levels of design.
Differentiation
Aesthetic, functional and market differentiation from competitors
Production and technological constraints
Increased product performance was not to affect that of the production process in any way
Double size
Management of a double size in the production line without impacting investment
3. DESIGN PROCESS
Scanning the project into its most relevant design stages.
Product Development Research
The process began with a cross-user analysis together with the client. User journeys, related needs and design insights were defined. This analysis, together with a competitive study and analysis of market feedback from past years, led to an optimization of the client’s brief.
Concept development
The concept had to take into consideration the production constraints of the production line. a “big” job was done to find characterizing shapes and innovative materials.
After an initial design phase, an internal realization of a POC was made to show to the client.
Then the first tests were carried out through the prototype and iterative cycles of improvements and revision.
Product Engineering
At this stage, the best materials that would ensure high performance on the product and high machinability on the production line were tested and defined.
The project was concluded with the delivery to the customer of all the technical documentation required for the production line.
Production
Cycles of changes and optimization of materials occurred as the project progressed to adapt to the technological choices implemented on the line, ensuring flexibility and total absence of lock-in in design choices.
4. PROJECT OUTPUTS
From the breakdown of the initial problems, some design solutions were proposed that were able to convert technical limitations into a structural renewal of the starting product
New system to be patented
Through the limitations of the material to be adopted and new technologies capable of manipulating it, the design effort resulted in a novel solution for the client.
The new structural system to be included in the filter met all technical requirements, improving compatibility between production costs and manufacturing processes.
Continuous Iterations
Despite the limitations of the materials that could be used and the new technologies capable of processing them, the design effort resulted in a novel solution for the customer.
Whatever your project challenge, we respond with innovation and concrete solutions to support and guide you in your advancement and growth process, in line with your objectives.
