Dyson

Dyson Ltd

2012-2015
Malmesbury, UK

My Role:

Design Engineering, Prototyping, Design for Manufacture

Tools Used:

Siemens NX (CAD), 3D Printing, Laser Cutting, Mill & Lathe

I was employed at Dyson for 3 years, where I worked as a Design Engineer on a variety of projects.


Beginning in the New Product Development team, I helped to refine product designs from first working prototype through to manufacture. This required numerous iterations, and a rigorous design/build/test programme.
I then worked in the New Product Innovation team, where I developed new product ideas from concept through to first fully functioning prototype. During this time, I presented work directly to James Dyson and other members of the executive team.



Both roles were very hands-on, with lots of time spent in the workshop building & refining physical prototypes. I also became adept at CAD, from quick proof-of-concept models through to production-ready designs.



Due to confidentiality agreements, I am unable to show any “behind the scenes” development work, or details of unreleased products I worked on.

I was employed at Dyson for 3 years, where I worked as a Design Engineer on a variety of projects.


Beginning in the New Product Development team, I helped to refine product designs from first working prototype through to manufacture. This required numerous iterations, and a rigorous design/build/test programme.
I then worked in the New Product Innovation team, where I developed new product ideas from concept through to first fully functioning prototype. During this time, I presented work directly to James Dyson and other members of the executive team.



Both roles were very hands-on, with lots of time spent in the workshop building & refining physical prototypes. I also became adept at CAD, from quick proof-of-concept models through to production-ready designs.



Due to confidentiality agreements, I am unable to show any “behind the scenes” development work, or details of unreleased products I worked on.

Dyson V8 Docking Station

I was the lead design engineer for the Docking Station assembly of the Dyson V8 handheld vacuum. Taking the design through countless iterations, I validated the robustness and performance of the product through a rigorous program of mechanical testing. To fulfil Dyson safety requirements, the Dock needed to be able to withstand a 30kg child hanging from the wand of the vacuum without breaking or causing the vacuum to fall out. I managed to achieve this while also optimising the design to significantly reduce the amount of plastic used compared to the previous generation.

Tool Attachment System

My other role on the project was helping to redesign the attachment mechanism for the various tools.
Previous generations of Dyson handheld vacuums had a frustrating system where the tool release button was mounted on the inlet nozzle of the vacuum, which meant the user had to press this button while at the same time pulling their hand away from the button to remove the tool - an awkward motion.
For the Dyson V8, we designed a "quick-release" system where the mechanism to release the tool is on the tool itself. I produced multiple prototypes with different mechanisms to achieve this goal, and tested each one to evaluate ergonomic benefits, tensile load limitations & cost implications.

See the dock & tool attachment system in action below: