Current studio project, work in progress…
HOTO Orbital Sander
The HOTO design redefines everyday tools with sleek aesthetics, intuitive interfaces, and smart functionality—enhancing usability and user confidence. Adding an orbital sander to the lineup would bring these values to surface finishing, blending performance with minimalist design for both pros and DIYers.
01. research
INTERVIEWS
I interviewed two industry professionals: Ben Jones, Director of the UC 1819 Makerspace, and Hayes Shanesy, a cabinet maker. Ben offered insights on tool use across skill levels from a teaching perspective, while Hayes provided practical input from daily professional use—together offering a well-rounded view of user needs.
BEN JONES
As an educator, he has different view of power tools, focusing on how beginners without experience would use them. Finds that orbital sanders are used regularly, and users put to much pressure on the sander.
HAYES SHANESY
He embraces an artisanal aesthetic, valuing the craftsmanship of handmade furniture and goods. He uses various orbital sanders depending on the task, each offering its own advantages and drawbacks.
BEN JONES
HAYES SHANESY
Miro board compiling research on potential improvements for orbital sanders, along with key factors to consider when purchasing.
ORBITAL SANDER CURRENT DRAWBACKS
POOR ERGONOMICS DESIGN AND USER FATIGUE
Many orbital sanders have bulky or poorly contoured grips, leading to discomfort and hand fatigue during extended use. A lack of vibration control can also contribute to strain on the user’s wrist and arm.
INCEFFICENT DUST COLLECTION
Standard orbital sanders often have weak or poorly sealed dust collection systems, resulting in debris escaping into the work area. This not only creates a mess but can also pose health and visibility issues during sanding.
LACK OF PRESSURE FEEDBACK OR CONTROL
Traditional models provide no feedback on how much pressure is being applied. Excessive pressure can damage surfaces or reduce the tool’s efficiency, while too little pressure may not achieve the desired sanding results—yet users often have to rely on guesswork.
Visited the team at Edward B. Mueller Company, a Cincinnati-based dealer of new and used woodworking machinery, to discuss their top-line Festool orbital sanders and explore potential areas for improvement and explore ergonomics, human factors, and affordance.
tool taredown
Taking apart an orbital sander helps inform the design process by revealing how its internal components function and fit together, offering valuable insight into ergonomics, construction, and opportunities for innovation.
brand involvement
HOTO “WE MAKE COOL TOOLS”
HOTO is a modern, design-driven tool brand that blends minimalist aesthetics with smart technology, creating sleek, user-friendly products that appeal to young homeowners, DIY enthusiasts, and design-conscious users looking for intuitive, stylish tools that fit seamlessly into their lifestyle.
SIMPLE ERGONOMICS
HOTO emphasizes smooth, continuous curves and a lack of exposed screws or harsh edges, creating products that are both ergonomic and visually refined.
INTEGRATED TECHNOLOGY AND LED SCREENS
Many HOTO products incorporate minimalist LED or OLED screens that provide real-time feedback, combining functionality with a sleek, futuristic interface.
DURABLE LIGHTWEIGHT MATERIALS
HOTO uses high-quality plastics and aluminum alloys to create tools that are sturdy enough for everyday tasks but light enough for comfortable, prolonged use.
ERGONOMIC COMFORT
Ergonomic intuitive grip and handle that supports prolonged use—while maintaining HOTO’s signature clean lines and modern design language.
02. Design
DESIGN GOALS
SMART DIGITAL INTEGRATION
Incorporate a simple display to show speed settings, battery life, and real-time pressure feedback—giving users greater control and awareness without adding visual clutter
SEAMLESS DUST MANAGMENT
Design an integrated, efficient dust collection system with a magnetic or twist-lock canister and clear visual indicators.
03. Model making
PAlm grip form ideation
Creating foam models of palm grips allows for quick, hands-on testing of ergonomics, helping refine the comfort, shape, and usability of the orbital sander early in the design process.
full FORM IDEATION
Combining the best features of rear handles and palm grips onto various bases using quick 3D-printed Blender models to explore ergonomic and functional possibilities
REAR HANDle FORM IDEATION
Building foam models of the rear handle helped me explore form, fit, and hand positioning while also testing trigger placement, allowing for quick adjustments to improve overall comfort and control.
hoto tech integration
After finding final form, Ideating ways to match the features to integrate with HOTO’s signature design language—where technology is seamlessly embedded in a minimalist and intuitive form. Focusing on how HOTO balances smart functionality with clean, simplified aesthetics.
3D modeling
Used Fusion 360 surface modeling to build the form, referencing a previous quick model. Imported into KeyShot to check surface tangency and ensure smooth transitions.
current status…
Model is currently being milled with a CNC machine, using 20lbs high-density foam for physical model prototype.
