Industrial Design: The Starting Point of Product Processing

In the process of bringing a product from nothing to something, industrial design plays a crucial role and can be regarded as the starting point of product development. It is by no means merely about dressing a product in a beautiful exterior; rather, it encompasses comprehensive and systematic work from user demand insights and creative conception to function planning, appearance shaping, and structural design, providing fundamental guidance for subsequent product manufacturing processes.

Starting from user needs, industrial design initiates the journey of product innovation. Designers conduct in-depth market research, using various methods to collect data and thoroughly analyze the behaviors, usage scenarios, and potential needs of different user groups. Take smartwatches as an example: research on fitness enthusiasts revealed their desire for real-time, accurate monitoring of metrics such as heart rate, exercise tracking, and calorie consumption during workouts, alongside requirements for quick and easy operation, long battery life, and a comfortable yet stylish wearing experience. Based on these needs, industrial designers focus on optimizing and integrating the sports monitoring functions when designing the smartwatch, while selecting lightweight, skin-friendly materials for the exterior and pairing them with simple, fashionable forms to meet users’ aesthetic and comfort expectations. This user-centered design approach establishes a clear direction for subsequent manufacturing processes, ensuring that the final product accurately targets the market and possesses strong competitiveness.

During the creative conception phase, industrial designers fully leverage their imagination, breaking free from conventional thinking to endow products with unique value propositions. For instance, in the early personal computer market, where product appearances were generally monotonous and functions relatively limited, Apple’s industrial design team boldly innovated, proposing a simple, integrated design concept that cleverly combined the computer’s main unit, monitor, and other components, resulting in groundbreaking products like the iMac G3. Its translucent colored casing not only made a strong visual impact, subverting people’s perception of traditional computers, but also set a trend in consumer electronics design. This kind of innovative design concept posed entirely new challenges and requirements for subsequent manufacturing processes, driving innovation and development in manufacturing techniques, such as breakthroughs in injection molding to achieve the color and texture effects envisioned by designers, ultimately realizing the unique aesthetic effect they pursued.

Function planning and structural design are key steps in industrial design to ensure a product's practicality and reliability, and they are also important parts closely connected to product processing. When designing a power tool, designers need to reasonably plan the layout and connection methods of core components such as the internal motor, battery, and transmission system according to the tool's functions. For example, to ensure stable torque output and flexible operation of an electric screwdriver, designers carefully design the transmission structure, select appropriate gear materials and parameters, and consider how to efficiently integrate the battery pack into the tool handle to achieve a comfortable grip and portability. These structural design plans directly determine the manufacturing and assembly processes of individual components in product processing. Complex internal structures may require high-precision machining processes to ensure dimensional and fit accuracy of components, and the assembly stage also requires strict process procedures and quality control standards to ensure product performance stability and consistency.

Processing Prelude: Finalizing the Design Plan

(1) In-depth Research to Understand Needs

In the industrial design process, in-depth research is a key step to accurately understanding user needs and laying a solid foundation for subsequent design work. Taking the smart speaker market as an example, market researchers collected a wide range of industry reports and conducted data analysis, discovering that with the widespread adoption of IoT technology, the smart speaker market is experiencing rapid growth. Consumers' functional requirements for smart speakers are no longer limited to basic voice interaction and music playback; there is an increasing demand for smart home control and personalized content recommendations.

At the same time, user interviews focusing on different user groups also yielded valuable insights. Young users pursue stylish and personalized designs, hoping smart speakers can become part of home décor, with a user interface that is simple and easy to use. In contrast, older users place more emphasis on voice recognition accuracy and convenient volume control, preferring simpler designs but leaning toward traditional and stable styles.

With the information collected through these research methods, industrial designers gained a clear understanding of the functional and aesthetic requirements for smart speakers. In terms of functionality, smart home control became a key development focus, integrating protocols from mainstream smart home brands to enable seamless control of devices like lights, curtains, and air conditioners. Regarding appearance, multiple colors and shapes were introduced to cater to the personalized needs of younger users, while for older users, a simple-to-operate interface with large font displays was designed.

(2) Creative Concept Development and Selection
During the creative concept development phase, designers engage in brainstorming, fully unleashing their imagination to infuse the product with a unique spirit. Taking the smart speaker as an example, designers approached it from different angles and proposed multiple design concepts. Some designers drew inspiration from natural elements, suggesting a tree-shaped smart speaker, with the trunk integrating the main speaker and control module, and the branches cleverly designed as adjustable speaker stands. This design is not only aesthetically natural but also allows flexible angle adjustments, providing users with a unique visual and practical experience. Other designers, focusing on a sense of technology, envisioned a spherical smart speaker made of fully transparent material, with visible internal components and a floating light effect, resembling a futuristic tech product with a strong sense of innovation.

After proposing numerous creative concepts, the design team selected the most promising solutions through multiple rounds of evaluation. The evaluation considered various factors such as user requirements, technical feasibility, budget, and market competitiveness. Taking the tree-shaped smart speaker as an example, although its design was unique, there were technical challenges, such as the stability and adjustability of the branch stands, and its high production cost, which could impact the product's market pricing and competitiveness. Meanwhile, while the spherical smart speaker had a strong tech appeal, it posed usability issues, such as less stable placement compared to traditional shapes, and the fully transparent material was prone to fingerprints and dust, affecting its appearance. After careful consideration, the design team ultimately chose a smart speaker design that combines a minimalist modern style with ergonomic design. This solution meets users’ needs for fashionable appearance and convenient operation while maintaining manageable technical difficulty and cost, making it highly competitive in the market.

(3) Plan Refinement and Improvement  
After determining the preliminary design plan, designers use professional design software such as Rhino and SolidWorks to transform conceptual designs into detailed design schemes, conducting comprehensive refinement of the product’s appearance, structure, and functionality. For the appearance design, Rhino software is used to precisely shape the curves of the smart speaker, repeatedly examining the size and proportions to ensure the overall form meets aesthetic standards while providing a comfortable grip. For color matching, multiple rounds of color testing and market research were conducted to select several stylish color schemes that can blend into various home environments, such as classic black and white or fresh light blue tones.  

In terms of structural design, SolidWorks is used for 3D modeling, detailing the internal acoustic structure of the speaker, the layout of electronic components, and the connection methods of the casing. To enhance sound quality, an independent acoustic chamber design is adopted, optimizing the placement and angle of the speakers to reduce sound resonance and interference. For the layout of electronic components, factors such as heat dissipation and signal interference are fully considered, and components on the circuit board are arranged rationally to ensure stability and reliability during long-term use of the speaker.  

For functional design, voice interaction features are further refined, optimizing the recognition accuracy and response speed of wake words, and increasing support for multiple dialects and foreign languages. In terms of smart home control functions, deep cooperation is established with major smart home brands to continuously improve the compatibility and control features of the smart speaker with various smart home devices, enabling users to easily control their entire home environment via voice commands.  

Throughout the process of plan refinement and improvement, the design team continuously engages in internal discussions and evaluations, optimizing and adjusting the design plan based on feedback. At the same time, the team maintains close communication with engineering and production teams to ensure the design plan is technically feasible and manufacturable, providing accurate and detailed design references for subsequent product processing stages.

Processing in Progress: Common Processing Methods and Key Points

(1) CNC Precision Milling

CNC precision milling is a high-precision CNC machining method based on digital control technology. Through computer-aided design (CAD) and computer-aided manufacturing (CAM) software, the product's 3D design model is converted into a CNC program. The control system of the precision milling machine precisely controls the movement of the machine's axes according to these program instructions, allowing the tool to perform cutting operations on the workpiece. In this process, the spindle drives the tool to rotate at high speed, performing milling, drilling, engraving, and other operations along preset paths, gradually transforming the raw material into product components that meet design specifications.

CNC precision milling is particularly suitable for machining products that require extremely high accuracy and surface quality and have complex shapes. In the field of precision mold manufacturing, the cavities and cores of molds often have complex surfaces and intricate structures. For example, injection molds for mobile phone cases feature fine textures, button holes, and various special-shaped structures, all of which require high-precision machining to ensure that the phone cases produced by the mold have accurate dimensions and a refined appearance. With its high-precision motion control and small-tool machining capabilities, CNC precision milling machines can accurately carve these complex shapes on molds, meeting the strict requirements of mold manufacturing.

During the machining process, precision control is a key point. The machine tool's own precision—including the straightness of the guide rails, the pitch accuracy of the lead screws, and the rotational accuracy of the spindle—directly affects machining accuracy. Therefore, selecting high-precision machine tools and regularly inspecting and maintaining machine accuracy is crucial. The selection and use of tools should not be overlooked; different materials and machining processes require matching suitable tool materials, geometries, and cutting parameters. When machining aluminum alloy materials, choosing carbide tools and properly setting cutting speed, feed rate, and cutting depth can ensure both processing efficiency and machining accuracy while reducing tool wear. Additionally, for some large or assembled products, controlling the accuracy of assembly joints is particularly important. Accurate programming and machining processes are required to ensure the dimensional accuracy and surface flatness of the joints, achieving seamless assembly and ensuring the overall quality of the product.

(2) 3D Printing
3D printing, also known as additive manufacturing, is a highly innovative processing technology. Its working principle is to build objects layer by layer according to three-dimensional model data. Unlike traditional subtractive manufacturing (such as machining) and formative manufacturing (such as casting and forging), 3D printing drives the material addition directly from digital design data, eliminating the need for complex molds and large-scale mechanical processing equipment, greatly simplifying the manufacturing process. During the printing process, the 3D printer follows numerous two-dimensional slices generated by slicing software from the 3D model and stacks the material layer by layer from bottom to top, eventually forming a complete three-dimensional object.

3D printing demonstrates many significant advantages in product processing. Its cost advantage is particularly prominent in small-batch production and customized manufacturing scenarios. In traditional manufacturing, producing small quantities of products often results in high unit costs due to expensive mold development and long production preparation cycles. In contrast, 3D printing requires no molds and prints directly from digital models, avoiding mold cost distribution and greatly reducing the cost of small-batch production. For personalized products, such as custom jewelry and medical devices, 3D printing can quickly produce unique items tailored to each customer's specific needs, meeting the market demand for personalized products.

The fast production cycle of 3D printing is another major highlight. During product development, designers can quickly create product prototypes using 3D printing technology, transforming abstract design concepts into physical models for design verification, functional testing, and appearance evaluation. Compared with traditional hand-made or machined prototypes, 3D printing greatly reduces prototype production time and accelerates product development iterations, enabling companies to bring products to market faster and gain a competitive edge.

In the aerospace field, 3D printing is used to manufacture complex aircraft engine components, such as turbine blades. These components have intricate internal cooling structures that are difficult to achieve with traditional manufacturing methods, whereas 3D printing can easily produce parts with complex internal structures, ensuring part performance while achieving lightweight designs, reducing aircraft weight, and improving fuel efficiency. In the medical field, 3D printing is widely used to produce customized prosthetics, implants, and surgical models. Doctors can tailor prosthetics and implants to fit the exact anatomy of patients, improving comfort and treatment outcomes; surgical models help doctors rehearse procedures before surgery, increasing surgical success rates.

It is important to note that 3D-printed products often require post-processing. Due to the material layering method and printing process limitations, the surface of printed products may be somewhat rough, and dimensional accuracy may vary. Therefore, post-processing steps such as sanding, polishing, and heat treatment are usually necessary to enhance surface quality and dimensional accuracy and ensure the product meets functional requirements.

(3) Silicone Duplication Molding
Silicone duplication molding is a relatively simple and cost-effective method for reproducing products, commonly used for the rapid production of small batches. The process mainly includes two key stages: mold making and product replication. In the mold-making stage, it is necessary to first create a master model, which can be produced through 3D printing, CNC machining, or manual crafting to achieve a sample with precise shape and dimensions. The master model is then fixed within a specific mold frame, and the prepared silicone material is poured into the mold frame to completely cover the master model. Once the silicone material has cured, the silicone mold is carefully separated from the master model, resulting in a silicone mold that is the exact inverse of the original model.

In the product replication stage, prepared liquid materials such as resin or plastic are poured into the cavities of the silicone mold. By using vacuum processes to remove air bubbles from the material, the quality of the products is ensured. After the liquid material has cured, the silicone mold is opened, yielding a product that has the same shape as the original model. To ensure product quality and consistency, strict control is required over factors such as silicone mold fabrication quality, the ratio of liquid materials, and curing conditions during the duplication process.

Silicone duplication molding is suitable for producing small batch products, typically ranging from a few dozen to several hundred units. This is because the lifespan of silicone molds is limited; as the number of uses increases, the accuracy and surface quality of the mold gradually decline, leading to instability in the quality of replicated products. Therefore, for large-scale production needs, silicone duplication molding may not be the most cost-effective choice.

Regarding material selection, silicone duplication molding can use a variety of materials, such as epoxy resin or polyurethane. These materials have good flowability and curing properties, enabling precise replication of the original model's shape and details within the silicone mold. Different materials possess different physical and chemical properties and are suitable for various product applications. Epoxy resin has high strength and hardness, making it suitable for products that require structural strength, whereas polyurethane has good flexibility and wear resistance, suitable for products that require some flexibility, such as replicas of rubber items.

However, silicone duplication molding also has certain limitations, especially in terms of dimensional accuracy. Silicone material inherently has some elasticity and shrinkage, which can inevitably cause dimensional deviations during mold making and product replication. Although some techniques can minimize these deviations, compared to high-precision methods such as CNC machining, the dimensional accuracy of silicone duplication molding is relatively lower and is generally suitable for products that do not have very strict dimensional requirements.

Behind the Scenes of Processing: Important Considerations Not to Be Overlooked

(1) Coordination Between Design and Manufacturing Feasibility

In industrial design, coordinating the design plan with manufacturing feasibility is crucial, as it directly determines whether a product can smoothly transition from a drawing to a physical object while maximizing cost-effectiveness without compromising quality. Even the most perfect design plan, if it ignores the realities of manufacturing processes and materials, can encounter significant difficulties during production, and may even be impossible to realize.

When designing complex electronic product enclosures, if designers pursue the ultimate shape by using overly sharp corners and ultra-thin wall thicknesses, from a manufacturing perspective, this can create significant challenges for injection molding. Sharp corners tend to concentrate stress during the molding process, leading to defects such as cracking in those areas; ultra-thin walls may affect the flow of molten plastic during injection, causing material shortages, deformation, and other issues, while also increasing the difficulty and cost of mold manufacturing. Therefore, during the design phase, designers need to work closely with process engineers to fully understand the characteristics and limitations of injection molding and optimize the design accordingly. For example, slightly rounding off sharp corners can enhance the product's aesthetic appeal while improving moldability; reasonably increasing wall thickness and using structural design to ensure product strength can satisfy functional and appearance requirements while allowing for smooth production.

(2) Material Selection and Appearance Performance
Material selection is a crucial decision in industrial design. Different materials not only determine the physical properties of a product but also have a profound impact on its appearance, so it is essential to carefully choose suitable materials based on the product’s positioning and function.

Take consumer electronics as an example. Metal materials, with their high strength, excellent heat dissipation, and premium feel, are often used for the casing of high-end smartphones, laptops, and other products to highlight their high-end quality and technological appeal. Apple’s MacBook series, for instance, uses aluminum alloy that undergoes precise CNC machining and anodizing treatment, resulting in a refined appearance with smooth lines, excellent heat dissipation, and meeting users’ demands for high performance and premium quality. On the other hand, plastic materials are low-cost, highly moldable, and available in a range of colors, making them widely used in mid- to low-end consumer electronics as well as products requiring creative appearance designs. Some electronic products for children, for example, often use brightly colored, cute plastic casings to attract young users. Injection molding processes can easily achieve various unique designs while reducing production costs, making the products more competitive in the market.

In addition to considering the physical properties and cost of materials, designers also need to pay attention to how surface treatment processes affect the appearance. The same metal material can exhibit drastically different looks depending on the surface finish. For example, stainless steel, after polishing, has a mirror-like surface with a strong modern and technological feel, commonly used in high-end kitchenware and bathroom products. After brushing, the surface has a delicate texture with a soft feel, often used in electronic products and household items to enhance the sense of quality and sophistication. When selecting materials, designers need to comprehensively consider the product’s positioning, the preferences of the target user group, and the product’s usage environment to choose the appropriate material and surface treatment, achieving a perfect integration of appearance and functionality.

(3) Control of Machining Accuracy
Machining accuracy is one of the key indicators for measuring product quality and plays a decisive role in both the appearance and performance of a product. During the manufacturing process, even extremely small deviations in precision can cause assembly problems and affect the overall performance and appearance quality of the product.

In the production of automobile engines, the machining accuracy of the engine block is crucial. Various parameters such as the diameters of the holes, the cylindricity of the cylinders, and the flatness of surfaces need to be strictly controlled within very tight tolerances. If the cylindricity deviation of the cylinder is too large, the clearance between the piston and the cylinder will be uneven, leading to issues such as engine leakage, reduced power, increased fuel consumption, and seriously impacting engine performance and reliability. Moreover, machining accuracy directly affects the product's appearance. High-precision processing can make the surface smoother and more even, with more flowing lines, enhancing the overall aesthetics and texture of the product. For instance, in high-end watches, the machining accuracy requirements for components such as the dial and case are extremely high. Through precision CNC machining and polishing, the surface of the watch achieves a mirror-like finish, presenting a delicate and luxurious appearance.

To ensure machining accuracy, multiple aspects need to be considered. Firstly, choosing high-quality machining equipment is crucial. Advanced CNC machining centers typically feature high-precision servo systems, precise transmission components, and sophisticated control systems, which enable more accurate motion control and thus ensure machining precision. Regular maintenance and calibration, along with timely replacement of worn components, are also key measures to maintain equipment accuracy. Secondly, properly selecting machining processes and parameters is equally important. Different processes have varying levels of precision; for example, grinding usually offers higher precision than milling. When selecting process parameters, factors such as the material properties, machining requirements, and equipment capabilities must be considered, with cutting speed, feed rate, and depth of cut adjusted appropriately to minimize machining errors. The skill level and responsibility of operators also significantly affect machining accuracy. Skilled operators can better understand machining processes and equipment operation techniques, promptly identify and solve issues that arise during machining, and ensure the stability of product machining accuracy.

Product Birth: Acceptance and Subsequent Optimization

(1) Strict Acceptance Standards

Product acceptance is a critical step in ensuring product quality. It acts like a 'gatekeeper' for quality control, involving strict and comprehensive processes and standards. In terms of appearance inspection, the overall design, dimensional accuracy, and surface quality of the product are closely examined. For example, in the case of a smartwatch, high-precision measuring devices such as a coordinate measuring machine are first used to accurately measure the watch's length, width, height, screen size, and button positions and dimensions, ensuring that deviations from the design drawings are within the allowed tolerance, generally controlled within ±0.1mm.

At the same time, the surface of the product is carefully checked for scratches, defects, color differences, and other issues. For smartwatches with metal cases, visual inspection and tactile assessment are used to check if the surface is smooth and even, without obvious processing marks; a professional colorimeter is used to measure the product's color and compare it with standard color cards to ensure consistency and accuracy, with color deviation controlled to a level imperceptible to the naked eye.

Functional testing is equally essential, carrying out comprehensive tests on all functions to verify whether the product meets design requirements. For a smartwatch, the heart rate monitoring function is tested using professional heart rate simulation equipment to simulate various heart rate values, checking the accuracy of the watch's measurements, with errors controlled within a specified range, such as ±5 beats per minute. When testing the sleep monitoring function, testers wear the watch to track sleep, then compare the data with professional sleep monitoring devices to assess the accuracy of sleep stage detection and data completeness. The smartwatch's activity mode recognition is also tested under different exercise scenarios, such as running, swimming, and cycling, to verify whether the watch can accurately identify the activity mode and record the corresponding exercise data.

Performance testing primarily focuses on the operational stability and reliability of products under different environmental conditions. Smartwatches are tested in extreme environments such as high temperature, low temperature, and high humidity. In a high-temperature environment of 60°C, the watch is run continuously for several hours to observe whether issues such as freezing, restarting, or functional abnormalities occur; in a low-temperature environment of -20°C, the battery life and normal operation of all functions are checked; in a high-humidity environment of 95% RH, the watch's water resistance and internal circuit moisture resistance are tested to ensure it can function properly in various harsh conditions.

When non-compliant products are identified, the corresponding handling procedures are immediately initiated. For products with minor defects, such as smartwatches with slight surface scratches that do not affect functionality, professional personnel are arranged for repair, using processes like grinding or polishing to remove scratches so that the appearance meets acceptable standards; for products with serious quality issues, such as those where functions cannot operate normally or performance is severely below standard, they are either reworked or scrapped. During rework, the cause of the problem is thoroughly analyzed, investigating design, materials, and manufacturing processes, with targeted improvement measures implemented, such as optimizing design plans, changing material suppliers, or adjusting processing parameters, to prevent similar issues from occurring in future production.

(2) Market Feedback and Product Iteration
Collecting market feedback and user reviews is an important basis for driving continuous product optimization and iterative upgrades. It serves as a 'weather vane' for product development, pointing companies in the direction of product improvement. Companies typically gather market feedback through various channels. Online, they use e-commerce platforms' review systems to comprehensively collect user evaluations of products, including advantages, disadvantages, and issues encountered during use; they also leverage social media platforms to monitor discussions and shares about products on Weibo, WeChat, Douyin, and other social platforms, extracting users' genuine needs and potential suggestions.

Offline, companies regularly conduct market research activities by organizing professional research teams to engage directly with consumers at sales terminals, asking about their experiences with purchasing and using the products, their expectations for the products, and suggestions for improvement; users are also invited to participate in product trial activities to observe their behavior and feedback during actual use, collecting their immediate opinions and feelings.

Taking a smart home product as an example, online evaluation analysis on e-commerce platforms revealed that some users felt the app interface was not simple enough and that functions were hard to find; social media discussions indicated that some users hoped the product could increase interoperability with more smart devices for a more convenient smart home control experience. During offline market research and user trial activities, users mentioned that the product's design was not aesthetically pleasing and did not match modern home decoration styles.

Based on this market feedback, companies will quickly organize the relevant departments to conduct in-depth analysis and research, transforming the feedback into specific product improvement measures. Regarding issues with the app’s user interface, the design team will redesign and optimize the app, simplifying operational processes, adjusting the functional layout, and making the interface more streamlined and intuitive, so that users can quickly find the features they need. To meet users' demands for interconnectivity features, the technical team will increase R&D investment, collaborate with more smart device brands, and develop new connection protocols and functional modules, enabling seamless integration and coordinated control between the product and various smart devices.

In terms of appearance design, designers will refer to current trends in modern home decoration, redesigning the product’s shape and color scheme to make it more stylish and better integrated into home environments. Through these product optimizations and iterations based on market feedback, the product can better meet user needs, enhance user satisfaction and market competitiveness, and achieve continuous development and innovation.