Project Overview

This project sought to redesign one of several common tools through a combination of group research and individual development.

Use Analysis

The first step of the project was to conduct an informal use analysis. This part of the project was done as a group, with Jennifer Abernathy, Lauren Janeway, Toni Walden, and I. During the analysis, Lauren and I acted as test subjects, while Jennifer took photos and Toni wrote notes.

Black & Decker jigsaw disassembly
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Disassembly

The second step of the project, also done as a group, was to disassemble a Black & Decker jigsaw. By taking the jigsaw apart into its components and arranging them on a board, we were able to get a much better idea of the tool's inner workings, allowing us to design with the actual mechanism in mind. From this point onward, all work was done individually.

Concept Sketches

With knowledge of the jigsaw's actual workings, and a recorded analysis of the tool's use, I now set about drawing new designs for the jigsaw. In this project, the sketches led to the design statement rather than the other way around, and my drawings explored a few radical redesigns as well as more cosmetic alterations.
Concept Sketches 1
 
Concept Sketches 2
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Concept Sketches 3
 

Design Statement

Model Process
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Redesign the jigsaw with a secondary grip, allowing the user to comfortably apply pressure directly over the blade for two-handed use while still allowing one-handed operation. Refine the aesthetics to create more geometric shapes near the blade, melting into comfortable, rounded shapes closer to the grips.

Physical Model

Finally, a physical model was built to validate the new design. The shape was molded out of plasticine clay with a foam-core buck and then cast in plaster. The resultant mold was filled with Bondo, resulting in a durable model with realistic weight. As per the assignment, the final model was a gray model, lacking some fine details but accurate in overall form. A parting line was added with a thin line of photo tape, indicating the three-part construction that positions edges where they will not bother users' hands.
Final Model (no parting lines)
 
Grip positions
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Final Model (with parting lines)