Ryobi Palm Router

A palm router with enhanced safety features for woodworking beginners.
Created
Summer 2022 | 13 weeks
Client
Ryobi (Unaffiliated)
Skills
User Research, Sketching, 3D Modeling, Prototyping
project brief
Routers can be a dangerous and unapproachable tool for woodworkers without much experience. Many key safety concerns are not as intuitive as other tools, and even relatively small mistake can have drastic consequences.

How might we design a palm router with enhanced safety features for woodworking beginners?
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01 | Research

Immersion Experiences

Conducted brief interviews with target users to identify potential opportunities and pain points.
Woodworking prosumer | first interview
This interview introduced me to a variety of power tools common in an at home wood shop. I talked through the function, maintenance, and safety concerns for each tool. As we discussed routers, it became apparent that many of the dangers presented were not as apparent as other common tools.
Professional luthier | second interview
After zeroing in on palm routers, I sought a user who was very familiar with their common issues. This interview illuminated a number of safety concerns that discourage even an experienced woodworker from reaching for this tool whenever possible.

Ergonomic Analysis

Dangerous second hand placement
A common placement for the user's second hand is on the baseplate of the router. This helps keep the baseplate flat to the top of the work piece, ensuring the bit travels perpendicular to the top surface. This creates an important safety concern regarding the proximity of the user's hand to the cutting bit. Some routers offer slight lips or a textured surface to minimize the possibility of injury, while others discourage this placement entirely.
Primary Control from cylindrical grip
The user's primary source of control comes from a cylindrical grip that is typically on the motor of the palm router, though some are gripped by the metal base. The user guides the tool along the cutting path with this hand, so an ergonomic grip is crucial for giving the user control to create precise cuts.

Task Analysis

01 | Set cutting depth
Necessary for creating accurate cutting operations. Be mindful of how much material is taken off in each pass.
02 | clamp motor in base
Ensures the motor will not slip during the cutting operation.
03 | plug in router
Plug in after changing bit and setting depth to avoid dangerous accidental activation.
04 | align with edge
Ensure baseplate is flush with cutting surface, then bring cutting bit close to the edge of the work piece.
05 | switch to "on"
Maintaining firm control of the router, switch the motor to the "on" position.
06 | Complete cut
Bring bit to work piece and move router slowly along a cutting path counterclockwise to the outside edge.
07 | Switch to "off"
Maintaining firm control of the router, switch the motor to the "off" position.
08 | Unplug router
Unplug the router before changing bits or adjusting depth to prevent dangerous accidental activation.

Design Goals

Ergonomic grip
Design a grip that is comfortable and secure, offering the user maximum control and precision.
Safer device startup
Create a system that ensures the user maintains control of the tool while switching it on and off, and that the device cannot be switched to "on" while unplugged.
Second hand safety
Reduce the risk of injury to the user's supporting hand by fully accommodating the baseplate hand placement.
Touch point heirarchy
Emphasize the primary interaction points on the tool to clarify the intended use and reduce potentially intimidating visual clutter.

02 | Ideation

Preliminary Sketching

03 | Refinement

Sketch Refinement

04 | Finals

Features

Two-Point Activation for Safe Start

Safe Second Hand Support on Base

Comfort Grip Maximizes Control

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