Design Optimization of Dyson Bladeless through Reverse engineering and DFM techniques

Academic

December 2024

Boulder

We reverse engineered the Dyson Bladeless Fan to optimize its design for manufacturability and cost efficiency.
A detailed teardown and DFA analysis revealed opportunities to reduce part count by 10–15%, especially by consolidating wire holders and base components.
We proposed four key design modifications that simplified assembly and minimized fasteners and redundant structures.
Material analysis showed PC/ABS dominance, with suggestions to shift select components to lower-cost alternatives like POM or ABS.
Ashby charts guided the selection of materials balancing strength, weight, and environmental impact.
We explored alternate manufacturing processes—like rotational molding and die casting—to reduce complexity and scrap.
Economic analysis using OME and breakeven models quantified potential savings across redesigned components.
The projected result includes a 20% reduction in assembly time and up to 15% savings in production cost.
Our cost models included labor, tooling, and equipment amortization, ensuring a realistic feasibility check.
This redesign preserved the fan’s performance while delivering a leaner, more cost-effective product.

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