Redesigned an outdoor grill/oven handle to reduce surface temperatures at user touchpoints, iterating through multiple prototypes to balance thermal performance, ergonomics, and manufacturing constraints.
Handle design iterations and testing setup
Design Challenges
The existing outdoor oven handle reached uncomfortably high temperatures during operation, creating potential safety concerns and poor user experience. The goal was to reduce touchpoint temperatures while maintaining structural integrity, fitting within existing assembly constraints, and keeping manufacturing costs reasonable.
Design & Testing Process
I developed multiple handle design concepts, focusing on geometric changes that would reduce heat transfer from the oven body to user contact points. Each iteration explored different approaches: material selection, air gap configurations, contact point minimization, and heat dissipation features.
Prototypes were fabricated and tested under realistic operating conditions to measure surface temperatures at critical touchpoints. This iterative testing revealed which design features were most effective and helped identify unexpected thermal paths that needed addressing.
Technical Considerations
The design required balancing competing requirements:
- Thermal performance (lower surface temperatures)
- Structural integrity (handle must withstand repeated use and force)
- Ergonomics (comfortable grip, intuitive use)
- Manufacturing feasibility (moldable/formable with existing processes)
- Cost constraints (minimal tooling changes)
Each design iteration was evaluated against these criteria, with thermal testing data driving design refinements.
Results
Successfully developed an improved handle design that reduced touchpoint temperatures while meeting all functional and manufacturing requirements. The redesigned handle was validated through comprehensive thermal and mechanical testing.
Skills Applied:
Thermal design, iterative prototyping, testing methodology, ergonomic design, design for manufacturing, data analysis