Casella.
Designing the pump that made asbestos air testing safer and faster.
From qualitative interviews and observational research through to industrial design for manufacture, we created a category-defining new product for British brand Casella. WMP were invited to design and develop the new Casella High Flow Pump, Vortex3: a device mainly used to measure asbestos levels in the air, and a crucial part of confirming an area is safe after asbestos has been detected or removed.
Sectors
Expertise
Background.
Industrial design for hostile environments.
Casella has provided smart and easy-to-use solutions for monitoring noise, dust and vibration since 1799.
High flow pumps like this one are typically used in hostile environments and exposed to rough treatment, so the new design had to be suitably robust and meet drop test requirements. Other requirements included being easy to decontaminate and waterproof to IP65.
The Solution.
From on-site research to a fully engineered, manufacture-ready pump.
Watching users work before designing anything.
We conducted an on-site visit with users to understand the process and identify the main pain points of existing pumps. We found major pain points related to charging, transport, forgetting equipment, decontamination and carrying units to location on site: products stored in vehicles in a disorganised way, limited set-up time meaning users prefer to carry as many units as possible in one go, 1.5m fixed masts that are harder to get through an air lock than 1m masts, unreliable access to 240V power on site, and product cleaning that has to happen inside the air lock using wet wipes or a small bowl of water, since a hose isn't feasible.
Turning site observations into a detailed user journey.
We synthesised our findings into a detailed user journey, which let us hone in on particular pain points and highlight the areas with the most opportunity to improve.
Narrowing many sketches down to two real routes.
We used our research as the basis for several sketch concepts, narrowed down to two routes. Both were modelled in 3D to produce semi-functional 3D prints and CGI imagery, and once a design was selected, we went through several rounds of prototyping and user feedback to refine the final design.
Engineering a self-contained unit that's simple to decontaminate.
The unique, patent-pending design is compact and self-contained, making it easy to carry multiple units to a site. Internal gaskets and a one-way exhaust valve help the pump meet the IP65 standard, so it can be washed after use for quick, easy decontamination.
Letting operators carry every pump they need in one trip.
Multiple units can be stacked together so operators can carry everything they need in one go, rather than making repeat trips to the van. The units slide together, and a sprung clip on the base locks them in place.
Reading the pump's status from across the room.
The interaction panel on top of the unit makes it easy to control the pump, with colour-coded LEDs that show its status from a distance. The panel has been over-moulded to prevent water ingress and recessed for protection.
Building in protection for the parts most likely to get knocked.
The unit features a thick moulded casing made from high-flow ABS, with delicate areas recessed so they're harder to damage. The handle also protects components like the mast and interaction zone if the unit is dropped.
Making sure nothing gets left behind.
The telescopic mast and integrated tube/filter store away neatly when not in use, cutting down the number of separate pieces of equipment a user needs to remember when packing their van.
Reaching up to 2 metres without losing control.
A telescopic mast extends to take samples at up to 2m, and a moulded handle gives an obvious, easy grip even while the mast is extended.
Ready to make brave ideas real?
Engineering every part for mass manufacture, not just the prototype.
WMP meticulously engineered every component, delivering detailed part files optimised for mass manufacturing alongside a comprehensive set of engineering and assembly drawings. Weatherproofing was a particular focus, with custom gaskets and strategically placed O-rings, and mushroom valves positioned in the latch recess to let air escape while preventing ingress and shielding them from direct cleaning jets. Vibration mounts and rubber feet minimise vibration from the pump for added stability and durability, and the internal layout was designed to accommodate two different battery sizes in a compact, easy-to-assemble package.
The impact.
A pump now marketed as award-winning, with real numbers behind the design.
The finished Vortex3 went on to market with a flow accuracy better than ±5%, a 2.5-hour runtime at 12 litres per minute, and a weight of around 2.2kg, light enough for operators to carry several units in one hand. The Vortex3 Pro adds Casella's Airwave App with Bluetooth connectivity, letting operators start, pause or stop a measurement run and check battery life and memory capacity remotely from a mobile device. Casella now markets the Vortex3 as award-winning, taking it from research through to a genuinely category-defining product.
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