Ergonomic Power Tool Handle

Problem Statement

Current power drill handle causes user fatigue during extended use. Design an ergonomic handle that distributes forces evenly, provides excellent grip, and accommodates various hand sizes.

Requirements

• Accommodate 5th to 95th percentile hand sizes
• Reduce wrist strain during overhead drilling
• Anti-slip grip in wet or oily conditions
• Integrate battery release button
• Visual differentiation from competitors

Constraints

• Two-shot injection molding (rigid + TPE overmold)
• Maximum grip diameter: 45mm
• Must accommodate existing motor and battery interface
• Cost target: < $3 per unit at 50,000 quantity

Deliverables

• CAD model with draft analysis
• Ergonomic study summary (anthropometric data)
• Rendering showing material finish
• Manufacturing cost breakdown