The design of this patented, low noise hair dryer comes from the development and optimization of a new fan, internal fan cases, and outer shell that increases air speed while reducing noise. The low noise was achieved by increasing air and noise efficiency to be able to run the motor at lower speeds utilizing aerodynamic principles, data analysis and 3D prototype iterations. The patented technology protects the user's hearing and facilitates the conversation between customer and stylist.
The handle is ergonomically designed to be able to use the controls easily with the thumb, and they are sunken in to prevent accidental activation. It features a new double action cold shot trigger button for easy activation while holding the barrel or the handle.

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Over 20 fan iterations and fan cases were 3D printed, and studied. Air speed and sound data was collected and analyzed until these components where optimized to reduce noise and produce more air flow. Different fin geometries were tested as well as their number per fan and angles, as well as the fan support blades.

A polyurethane foam mock-up was carved by hand to further refine the design concept and get a closer feel of the final product.

A complete 3D model in Rhino was created adding all the internal and external parts.

Final Rhino 3D render:

Prototype development: All parts were 3D printed in a Stratasys FDM machine using ABS plastic. A fully functional prototype was built for review.

This innovative dual action button helps the stylists use the cool shot button when the dryer is held by the barrel.

A factory off tool sample is evaluated to make sure it meets the performance desired and UL standards.