FESTOOL CONTOUR
Ergonomic Innovation for Auto Body Professionals
Design Dilemma
Current sanders are too large and uncomfortable, causing ergonomic issues like carpal tunnel and chronic pain.
Target
Automotive mechanics and body shop professionals performing frequent, intensive sanding tasks. Including those in similar business where an orbital sander is an essential.
Solution
Redesign the rectangular orbital sander with an enhanced grip and optimized size to improve comfort, control, and efficiency.
Applications
Critical auto body stages: Sanding body filler, paint prep, smoothing primer, and final polishing.
“Small inconsistencies compound into major quality issues.”
LEAD BODY TECHNICIAN • 2+ YEARS EXP
The User: Aaron
Aaron works in a high-volume environment at Caliber Collison. His Job requires precise refinishing of dents and scratches where even a millimeter of error can lead to costly rework. He values efficiency and tools that guarantee repeatable accuracy.
High Volume
Precision
Efficiency
USER RESEARCH
Egonomic Analysis
MARKET & CONSUMER INSIGHTS
Ergonomic & Design Language Analysis
COMPETITIVE LANDSCAPE: VISUAL BRAND ATTRIBUTES
Ergonomic and Design Language Analysis
IDEATION
Thumbnail Exploration
Focused Direction
Inspired by mouse forms- Explored contoured handle forms to support natural grip and finger placement; determined physical prototyping would best inform further design iterations
TASK ANALYSIS
EMOTIONAL EXPERIENCE
MODELS
Form Concepts 01
Crafted hand models via bandsaw and 3M adhesive
FRONT
SIDE
BACK
FORM 1
FORM 2
FORM 3
FORM 4
User Feedback (n=10)
FORM 1
Dimensions were too wide and bulky for precise operation; orientation purpose remained unclear during user testing
FORM 2
Geometry shape proved unfeasible for grip applications
FORM 3
Strong handle orientation; however, the grip diameter was too slim to manage proper finger grip orientation
KEY TAKEAWAY: FORM 4
Identified as the optimal ergonomic solutions. The volume provides superior hand-accommodation
IDEATION PHASE 01
Form Concepts 02
Hand Comparison (n=11)
FORM 3
Large-hand optimized; over-scaled for smaller users.
Developed a "Universal Fit" geometry, merging Phase 1 handle profiles to optimize vertical height and grip curvature.
FORM 1 & 2
Focused on handle length and thumb contour.
FORM 4
Small-hand optimized; under-scaled for larger users.
Female Hand
FORM 4
Male Hand
KEY TAKEAWAY:
Testing revealed a size disparity between user hand profiles. To achieve universal accommodation, the next iteration synthesizes these forms into a median-scaled profile to ensure comfortable palm contact for all grip spans.
IDEATION PHASE 02
FORM 1
FRONT
SIDE
BACK
FORM 2
FORM 3
Female Hand
FORM 3
FORM 4
Male Hand
Hand-Made
Form Concept 03
Combined set 2’s width and finger grooves
Standard 5.24 x 3.25 in. Festool Abrasive Sanding Pad
Too long
CNC-Made
Too wide
Too large diamater
Needs larger diameter
Added thumb groove
CNC
Too small- Body, Motor, Dust Port
Too long-Handle & Body
Motor fits but handle too wide
3D PRINTS
Thumb Contour Testing
Thumb contour was refined to create a smooth transition into the top of the handle, improving control while blending materials.
FINAL TOUCHES
High Fidelity
Final Prototype 3D printed in PLA and CNC-machined from high-density foam; surfaces were refined with Bondo and finished with paint primer.
FINAL MODEL
CAD
Motor 1:
For general shape understanding and scaling
Motor 2:
Final motor with further detail
CAD 1:
Thumb contour has separate layers
CAD 2:
Thumb contour blended into one surface
