For this project, I wanted to develop a durable and user-friendly Dremel Rotary Tool for makers that is powerful yet enables good control for fine detail work while also working with existing Dremel universal systems.
Dremel Redesign
Users
Ben Paik
A maker and content creator. He uses recycled skateboards to make just about everything from bowls to conference tables. Due to the small size of his shop, he needs his tools to be extremely versatile.
Roxie
Loves making replica props from movies and attending conventions to show off her work. She uses sanding tools to refine her work and smaller engraving tools to add detail. She needs a tool that does both.
What’s your biggest complaint about current Dremel rotary tools?
“The balance and grip sometimes hurts my hand”
“Very heavy”
“It’s hard to control”
“There are guards around the power switch and speed control that are painful on the hand”
“Not powerful enough.”
“The handle is awkward for detail work”
What do you normally use your Dremel for?
I sent out a survey to a few Facebook groups as well as my fellow classmates and found out that most people use their Dremels primarily for sanding and engraving. Of the 43 people who responded 28 responded with sanding or engraving. From this data and other questions in my survey, I directed my designs toward those areas.
Operation
First, the spindle needs to be locked. Next, the collet nut is loosened. The desired bits can now be inserted or removed. Depending on the job different bits will be used. Finally, the collet nut can be tightened with the included wrench. If the Dremel is battery powered it will need to be fully charged before use. If it is corded the Dremel will need to be plugged in.
Once a bit is inserted the Dremel can be turned on and the speed adjusted to the desired level. Now the work can begin. Once finished using the Dremel it needs to be turned off and recharged or unplugged from the wall and put away. The user should also be wearing safety glasses and, if needed, a dust mask or respirator.
Design Goals
Develop a durable and user-friendly Dremel Rotary Tool for makers that is powerful yet enables good control for fine detail work while also working with existing Dremel universal systems.
DREMEL BRAND RESEARCH
Ideation
Direction One is heavily inspired by the current Dremel products and focuses on brand language more than form. These Dremels would be produced with traditional injection molding with ABS and TPU plastics.
Direction Two is more industrial in form and feel. Inspired by dental and industrial machinery these forms are heavy in the hand and would be made from cast aluminum then machined to add knurling and other details.
The final design is focused on ergonomics and how the user interacts with the device. The large protrusion on the bottom of the device fits into the palm allowing the weight of the tool to be more evenly distributed. I felt the Dremel styling and plastic construction were more appropriate than the cold metallic finish of Design Two.
This Dremel is focused on making it easy to operate the tool while still providing good control. To achieve this I went through several sketch ideations. Next, I moved to sculpted foam models then CAD models in Fusion 360. I printed out a dozen versions until I had the 3D model exactly how I wanted. A key feature that I included was the integration with Dremel’s current collet and threaded grip systems. This allows my design to work with any of the existing Dremel attachments and bits.
