Aimant | Gross Design Studio

CASE STUDY | CORDLESS HAIR DRYER: AIMANT

THE CHALLENGE:

The power cord was a once-necessary feature that, now, with innovations in battery technology, charging, and heating element may soon be viewed as an obsolete remnant in the evolution of the appliance.

THE INSIGHT:

Identifying issues with the appliance’s user experience highlights a need improvement. Removing the power cord prompts exploration of battery-powered solutions. A folding or collapsible design significantly reduces storage footprint and offers charging orientation on its base.

THE DELIVERY:

The Aimant Project created an elegant solution to the tangle cords of everyday appliances. Through rigorous design conceptual design, technical research, and iterative 3D modeling, the delivered

3D printed prototype sets the hairdryer apart from mundane.

Battery Insights

Cutting the cord on one of the most power-hungry appliances—the hairdryer—has long a challenge. A thorough examination of patents and product lines reveals a notable absence of viable cordless options. However, advancements in battery technology, including faster charging, compact designs, and extended lifespans, are paving the way for innovation. With the of wireless charging and decreasing costs, the cordless future isn’t just a possibility; it a necessity that is finally within reach.

History of Innovation

Pored over a century of design moves—from the first handheld hairdryer in 1920 to modern adjacent tech—to see what had changed, and what hadn’t. Aerodynamic forms like turbines, aerofoils, and fuselages offered fresh inspiration.

With those cues and a handle on the technical constraints, sketching began. The folding form emerged fast—both to shrink the footprint and to nest seamlessly into a charging base. Sometimes, the smartest features are the ones that do double duty.

Sketching/ Ideating

The idea: a hairdryer so well-designed, it deserves to live on the counter—not hide in a drawer. Early sketches leaned fully into sci-fi vibes, pushing form as far as function would allow. From there, the process became one of refinement—balancing bold shapes with clean utility and building visual harmony between the dryer and its charging base.

Model Iterations

Stationary pegs provide the axis upon which the handle hinges. The rear intake side of the hairdryer was intentionally created larger than the front exhaust in order to accommodate airflow restriction around the handle bay inside the main housing and narrowing the airflow chamber for increased output force.

REFINEMENT

The model was crafted so that it looks equally elegant regardless if in use, folded, or charging between uses. The charging base was derived from the inverse geometry of the main housing. This enables a natural fit for the hair drier while charging and ensure a proper charging orientation.

A scratch-free fabric interior protects the hair drier’s polycarbonate surface. The charging base mesh features the similar specifications as the popular Google Home such as hydrophobic and antimicrobial polyester/nylon coating. Overlapping ‘lips’ and annular snap fits were added to the rear mesh and main housing to insure a tight but impermanent fit for prototyping.

CRAFTING MODEL ITERATIONS

Careful component research and CAD modeling laid the groundwork for a prototype that could test key mechanics—button placement, hinge rotation, and whether wiring could pass cleanly through the fold without binding. Engineering models were exported from CAD for a clean, satisfying snap-fit assembly.

Careful component research and CAD modeling laid the groundwork for a prototype that could test key mechanics—like button placement, hinge rotation, and whether wiring could pass cleanly through the fold without binding. Solid models were exported from Rhino with tight tolerances, aiming for a clean, satisfying snap-fit assembly. With many failures, revisions, and re-calibrations of the printer and model geometry, the model was able to achieve outstanding fidelity. Delicate sanding, painting, and hand finishing created a crisp showroom-quality prototype.