FESTOOL DEXTRO

A student project exploring the visual brand language of FESTOOL, resulting in a multi-material specialty saw for professional craftspeople.

Role

Student Product Design Project

TOOLS

Fusion360, Blender, Adobe CC

TIMELINE

12 Weeks, Summer 2024

PRODUCT DESIGN
BRANDING

OVERVIEW

The Challenge

Brand alignment Learn how to analyze and design within an existing visual brand language (VBL).

Product design Design a line extension for an existing power tool brand using qualitative and quantitative research.

Research

RESEARCH

Research Overview

User Research Interviewing handheld power tool users, user experience mapping to identify pain points.

Brand Research Studying the FESTOOL visual brand language,  identifying FESTOOL enthusiast’s needs, and analyzing the existing FESTOOL product catalog for opportunity areas.

Market Research Locating opportunity areas by comparing competitor products

User RESEARCH

Field Interviews

“It’s a real handy little saw. You don’t have to carry those big saws around like the one I showed you, you can do almost just as much with this as you can with any of those other saws.”

- Mac R., Independent Contractor

BRAND AND USER RESEARCH

FESTOOL Enthusiast Survey

FESTOOL has an active forum where enthusiasts discuss their experience with FESTOOL products.

Using insights from immersive research, forum enthusiasts were surveyed (qualitative and quantitative) about their tool collection, FESTOOL brand perception, and experience with FESTOOL products. Of 11 survey respondents:

brand and user research

FESTOOL Enthusiast Immersive Research 

Visiting the workshop of a FESTOOL enthusiast allowed for hands on experience with 25+ FESTOOL products.

Key takeaways Workflow overviews per tool, grip placement logic, user ergonomic concerns, feature requests

This research was done collaboratively with Zoe Hong, Gabriella Gibson, and Duy Nguyen. Photos by Duy Nguyen.

MARKET RESEARCH

Opportunity Insights

Research on the FESTOOL product catalog shows the lack of a versatile, compact handheld cutting implement, which would be solved with the inclusion of a subcompact circular saw.

The subcompact handheld circular saw (SHCS) is available from both notable (Makita, DEWALT, Milwaukee, RIDGID) and generic brands. Market research revealed the lack of a professional grade, sleek version of this device, presenting an opportunity for brands such as FESTOOL.

product research

Angle Grinder Teardown

A handheld circular saw was disassembled to better understand what components are found in a handheld cutting device. Unlike an angle grinder, the subcompact saw oscillates perpendicular to the surface.

The teardown informed the decision to use a brushless motor for its minimal weight and volume.

Concept Development

early ideation

Sketching and Early Models

Early sketches explored how to apply FESTOOL form language to the handle and head assembly. Concepts are designed around the FESTOOL 4.0 AH battery.

Sketches and foam models were created cocurrently to explore the same ideas in both 2D and 3D space.

concept development

CAD Development

DEXTRO was modeled in Fusion360 over 60 iterations. The design uses a FESTOOL 4.0 AH battery which (modeled based on reference photos).

  • Early models were rough blockouts with focus on silhouette and internal and external component position.

  • Later models focused on surface transitions, user touchpoints, and other fine details.

Final Concept

Final concept

Detail View

DEXTRO is features the FESTOOL EC TEC Brushless Motor and HighPower 18V 4.0 AH battery pack.

Final concept

Product Features

Final concept

Surface Study Model and User Validation

A physical model was made using CAM such as CNC milling and 3D printing. The model was used:

  • as a role-play prototype in ergonomics validation.

  • to analyze how light interacts with the surfacing in real life.

  • as a visual aid when presenting the product to final critique

Final concept

Project Learnings

DEXTRO was presented at final critique to peers and industry professionals.

Key takeaways from this project:.

  • Qualitative research methodologies, and how to analyze and display findings

  • Construction and organizational techniques for complex, multi-part assemblies

  • How to prioritize/deprioritize tasks/features in order to meet a deadline/deliverable