Description:

The challenge of this design development was to create a functional product which once the installation was completed creates the illusion of the absence of any product.

The aim was to create an interior air movement grille which is seamlessly installed into the ceiling during the construction of a room.

To achieve this the design had to consider all aspects of the product, its functionality, the materials it is made from, how it is manufactured and the installation process which would result in a perfect finish.

By researching the building processes associated with the installation of plasterboard ceilings and a detail of this type it was identified that the critical point for the success of the design was where the edge of the grille meets the plasterboard. To achieve a robust and truly seamless finish required this to be a plaster-to-plaster connection.

To develop and manufacture this connection the design team worked with a local artisan supplier skilled in making bespoke moulded plaster components to create a unique plaster ring which forms the integral connection point of the product.

The design and development of the product then focused on integrating this unique material into a functional product that could be manufactured in volume production.

Using sketches, CAD and prototypes the design and form of the grille body has been shaped and tested to ensure it provides space for the required airflow to achieve the product function but also gently cradles the delicate plaster component protecting it from impacts during assembly and installation.

The robust design and materials of the grille body allow it to be securely fastened to the framing structure of the building prior to the installation of the plaster board. This ensures a strong connection to the building which is essential to a robust final finish but also suits the standard building and plastering processes.

The central part of the grille is removable allowing the air movement ducting to be secured to the tapered spigot without having to enter the ceiling space. This central part can also be easily painted to match specific ceiling colours or even be replaced with a light panel to provide further options for the customer to create the exact finish they want.

Even the packaging of the product had to be designed to include supports and structure to protect the critical plaster component and ensure it arrives to the installer undamaged.

The outcome for this development is an air movement grille which showcases the innovative design, care, craftmanship and precision required to create a simple product which through its success goes unnoticed.