top of page
Course Name: Design For Sustainability Lab
Time Duration: 14 Weeks
Project Brief:
In this sustainability focused studio class, we were asked to redesign a product that is heavily involved in peoples' daily life and making it more
sustainable to use. I teamed up with Freddie Jiang, another student in product design major, to carry out the redesign for a compact air purifier
from Levoit. In 14 weeks, I was responsible for product category research, LCA analysis, design development, material research and final
prototype making.
Meet Our Team
Kevin Zhao
Freddie Jiang
Table of Contents
-
Product Introduction
-
Product Analysis
-
Filter Break Down
-
LCA Analysis
-
Env Impact Report
-
Design Goals
-
Solution Exploration
-
Concept Development
-
Concept Refinement
-
Product CMF
-
Data Comparison
-
Sustainability Analysis
-
Take Back Program
-
Our Future Vision
-
Prototype Making
-
User Experience
Section 1: Product Research
Levoit Core Mini
a1
Product Info:
Brand: Levoit
Trim Level: Compact Air Purifier
Device Dimention: 6.5 x 6.5 x 10.4 inches
Product's Ideal Covering Range: 17 square meter
Interface Design:
One Touch Operation
Aroma Intake:
Aromatherapy Allowed
Air Purification:
HEPA Air Filter
Product Analysis
1
2
3
5
4
6
7
9
8
10
11
12
1. Top Cover
2. Top Shell
3. Circuit Board Housing
4. Circuit Board
5. Aroma Case
6. Air Outlet Extractor
7. Motor
8. Fastener Screws
9. Charger
10. Air Vent
11. Air Filter
12. Filter Housing
We purchased this desktop air purifier from Amazon. After we used the product, we tore it down and labeled each part in arrangment to see how many different materials were used on the product. In the tear down process, we found out some design faults like the small air holes on the No.12 shell were
not dust-friendly for long term use.
Filter Break Down
11
HEPA Filter
Besides the air purifier itself, we also dived into the filter analysis by separating the layers to figuring out how it works. Base on the research, each HEPA filter can last up to 6 months with constant daily usage. However, the filter can not be cleaned and recycled once it reaches its lifespan. In average, most
of users will consume at least 5 air filters in 3 years before their compact air purifiers reach the lifespan.
a2
Section 2: Env Impact Study
Life Cycle Assessment
1/4
We made a LCA chart base on the raw materials for producing the parts off the product. Then we broke down the manufacturing process of making
each part from the material category. This process was time consuming, but it gives us a more intuitive understanding of the requirements for production and assembly. From combining information and simplifying the map, we are able to mark the energy use knowing what impact it does to the environment
at each stage.
Data Report Explanation
Sustainable Mind Report:
Based on the BOM, over 70% of the components on the product are made out of plastics.
Okala Impact Assessment Form
By analyzing the input digits, we discovered that 70% of the product's components are plastic-based. While many of these plastics are recyclable, their processing often involves energy-intensive and CO2-emitting transportation and re-manufacturing, contributing to global warming. Beyond plastics, the HEPA filter becomes unrecyclable after use due to lingering toxic particles in its layers. Consequently, replacing the filter generates non-recyclable industrial waste that poses disposal challenges. Data was calculated using "Sustainable Minds"
Design Goals
![IUDXR010-no-plastic-1575683474586 [Converted].png](https://static.wixstatic.com/media/789f5e_6e01b683736345b488fc7e5914998155~mv2.png/v1/fill/w_182,h_182,al_c,q_85,usm_0.66_1.00_0.01,enc_auto/IUDXR010-no-plastic-1575683474586%20%5BConverted%5D.png)
Dematerialization
(Less Plastic Usage)
Filter Condition
Monitoring
Extended Filter
Lifespan
Intuitive Smart
Home Control
a3
Section 3: Design Development
Solution Exploration
Once we figured out how air purifier works, we proceeded to do our own design ideations based on the design criteria. At this early stage ideation, the main focus for us was to get our ideas out to improve the sustainability of the product in each category of design focus. From the paper, we were able to see the design pattern and find the most balanced design direction to follow.
Concept Direction
Based on the evaluation of the ideations, our design direction is formed. We repurposed the Kapton material in the filter to make the HEPA filter last even longer. We reduced the use of plastics by packaging the main components in the core of the unit and placing the air filter layers outside as the supporting shell.
The new introduced Kapton film is a material that can adhere the micro-size particles remaining in the air actively. It is flexible enough to be curved and washed. (The new material application was tested in the lab by an unviersity in South Korea in 2018.) By adding the Kapton flim as the first layer, the HEPA filter's life span will be well extended to meet our goal.
Concept Development
To enhance the purifying efficiency of the built-in air filter at the bottom, we increased the air passage volume by enlarging the product' height. As the explode view shown, the air induction becomes more efficient than our first design.
Fabric
Cover
Kapton
HEPA
To make the product easier to maintain, the filter is integrated in the device as a modular unit.To replace the used filter, user can simply unscrew the used one and take it out of the device. With the help of fabric cover and additional Kapton layer on the filter, users now can rewash the filter cover for having a longer life span on the HEPA layer.
Air Out
Air In
We redesigned the inner components to optimize the air passage efficiency through the device. The filter and fan are put next to each other forming an
air tunnel for directing the incoming air through the fan blades. The upper cover and conduction vent form a "Slow Down Zone" to speed up the clean air spreading out of the device from the top.
CMF Directions
1/4
Prototype Making
1/4
This slide show mainly shows the making process of the 3D printed full-scale prototype from raw prints to a finished unit.
Physical + Digital UX
To make the product more convenient to use while maintaining a homey look, we updated the physical control panel with fabric wrapped touch buttons.
We also developed an App for users to make further adjustments on the device remotely.
Users can use the Levoit App to control the settings remotely. The smart control also allows device to monitor the filter condition and reminds users when they need to replace their filters.
a4
Section 4: Original vs Redesign
Data Comparison
Before:
After:
As the charts shown, we can see our redesigned product used way less materials comparing to the origional one. On top of the that, the amount of
metal fasteners are also reduced with the new inner components refinement.
VS
The impact report also gives us a better understanding of the sustainability improvement we made in the redesigned model.
Sustainability Improvement
Before
Regular HEPA Filter
After
Redesigned Filter
Used Filter Take Back Program
In the App, users can sign up for a take back program which they can return their used filters at Levoit's prefered pots collecting for disposal. In return, people who returned the used ones will receive a discount on their next purchase.
Our Future Vision
1/2
Our future vision is to create a network that collects air quality data from every user with the help of integrated air index sensor on each device.
Alarms Emergency Response
Arises Communities' Responsibility
Reflects Our Eco-Footprint
With the boundary-less data network, the potential of the feature will open up more possibilities which more useful information can be shared for different
purposes in regard to air quality notification.
Final Model & Packaging
bottom of page