Solved an uneven browning issue in the Ninja Combi cooker through rapid prototyping and testing of airflow modifications, leading to design changes that were implemented in the mass-produced product.
Sheet metal airflow vanes and cavity geometry prototypes
Design Challenges
The Ninja Combi was experiencing uneven food browning in the front corner due to lower temperatures in that zone. The solution needed to fit within the existing ceiling cavity, avoid significant cost increases, and maintain cooking performance for other foods—all within a tight development timeline.
Rapid Prototyping Approach
With limited time to identify the optimal solution, I established standardized testing procedures (SOPs) to ensure repeatability and minimize operator variability. This allowed for quick, reliable comparison between different design iterations.
I fabricated and tested multiple approaches:
- Sheet metal airflow vanes to redirect air circulation
- Modified heating element geometry
- Altered ceiling cavity geometry (prototyped using formed metal over 3D-printed molds)
Each concept was evaluated through thermal testing and food-based KPIs to verify improvements in browning uniformity without negatively impacting other cooking functions.
Technical Execution
The project required hands-on fabrication skills—quickly bending and forming sheet metal components to test airflow theories, creating makeshift fixtures to modify existing units, and validating that prototype materials could withstand operating temperatures.
Nominal temperature testing and systematic data collection helped identify which design changes had the most impact. The iterative approach allowed us to rule out ineffective solutions quickly and focus resources on the most promising directions.
Results
The heating element configuration and upper corner cavity geometry were both redesigned based on testing results and successfully implemented in production units. The project demonstrated the value of rapid prototyping and systematic testing when solving thermal/airflow challenges under time pressure.
Skills Applied
Rapid prototyping, sheet metal fabrication, thermal testing, test methodology development, data analysis, design validation, cross-functional collaboration