Stackable Carpet Drying Fan
2021 – 2022
THE PRODUCT
When disaster strikes and properties are severely flooded, water damage restoration companies rely on specialized equipment to mitigate the damage quickly. Among these tools are low-profile air movers – compact, stackable fans designed for easy transport, durability, and high airflow performance. KleenRite MFG partnered with DiMonte Group to design a next-generation air mover from the ground up.
MY CONTRIBUTIONS
As the lead Industrial Designer on this project, I collaborated closely with mechanical and electrical engineers to develop the product. My contributions spanned the entire design process, from initial brainstorming and styling sketches to detailed production CAD. I also participated in prototype testing to ensure the product met both functional and aesthetic goals, delivering a durable, efficient solution for the restoration industry
INDUSTRIAL DESIGN SKETCHING
FINAL SKETCH
This final sketch combined all of the aspects the client liked about the initial sketches in an attractive and robust form.
Features:
- Designated channel for cable wrapping
- Lead in for fan stacking
- Rear handle in line with center of mass
- Grip points at front and sides
- Housing color break for a custom accent color
- Flat sides and back allow fan to balance on its sides or back to dry along a wall, or up to a ceiling
PROTOTYPING AND AIRFLOW TESTING
Rather than relying solely on simulation, I conducted hands-on airflow testing using full-scale FDM prototypes.
A working prototype was incrementally modified using tape, clay, foam gaskets, and flexible plastic sheets to adjust internal airflow paths. Airflow was measured in CFM after each change, creating a rapid test-and-learn cycle: modify, test, evaluate, repeat.
As testing progressed, I made more significant geometric changes directly to the prototype. In one instance, sections of the housing were cut and replaced with newly printed geometry to push the side walls outward by 0.75″, improving airflow performance.
This iterative approach allowed me to converge on an optimized internal geometry based on measured results rather than assumptions.
FINAL PRODUCT
LEARN MORE
The Derecho retails for $365 on the KleenRite website. It is available in black or red.