Product design improvement for a tumbler with lid

the full research-to-design improvements made for Brumate's Toddy Tumbler and Bev-Lock Seal 🧋

OVERVIEW:

The motivation for this project is the design improvement for the tumbler that I own which is Brumate's 40oz variant tumbler with a handle and a lid. The issue was the ease of cleaning for the gasket and lid that is a problem that an encounter as a user. To validate this idea with the intention to tackle ease of cleaning, accessibility, and customization, we employed a derivative approach, building upon existing products through market research down to design architecture.
These are the final CAD designs that we did that highlight changes in the gasket and the lid. Notable differences from the sold physical item is that there is a slot for a protrusion that makes it easier to get the gasket to clean it.

METHODOLOGY:

Market Research: Online surveys were conducted to gather data on user preferences and usage patterns, focusing on the importance of easy cleaning.

Prioritization Matrix: Customer needs were scored, with durability, leak-proof design, and ease of cleaning identified as high priorities.

Concept Generation & Selection: Multiple lid concepts were developed and evaluated based on criteria such as drying time, accessibility, ergonomics, and compliance with regulations. An “Improved Snap-Seal” concept was selected for further development.

Concept Scoring: Concept A (Improved Snap-Seal) was selected as the most promising design based on a concept selection matrix, scoring highest in improvements over the referenced design and lowest in deterioration points. The selection criteria included drying time, accessibility features, ergonomics, ease of disassembly, user-friendly fasteners, compliance with regulations, and perceived easy instructions for cleaning.

Unit Cost Model: The cost model estimates per-unit costs for different lid designs (Angled Screw Cap, Twist Lid, Wide Mouth), including material, labor, packaging, marketing, and administrative expenses. Selling prices are calculated with a ~30% profit margin.

Specification Trade-offs: Trade-offs exist between variety and cost (modular design vs. manufacturing complexity), durability and weight (material selection), and design and compatibility (unique look vs. universal fit).

LEARNINGS:

This project highlights the product design approach convention to define the product development and organization, product planning, customer needs, product specifictions and concept generation with our suggestions to provide an improved gasket alternative with a protrusion and curved interior within the lid for ease of cleaning. You may check the full documentation of our approach below as well as the presentation that we did for this project.

Note: CAD model is available upon request. Comment below!

PS. Shoutout to my co-implements for this project; Shaya for co-developing the CAD; Gabby, Peter, Elmo and Ela for the concept generation.

Report of our product design for improvements for tumblers emphasizing ease of cleaning.
Presentation video for our product design approach