DATE:
INSTITUTE:
COURSE:
SKILLS:
Fall 2025
Duke University Pratt School of Engineering
Advanced Design & Manufacturing
• Design for Manufacturing
• 3D CAD Modeling (Autodesk Fusion)
• 3D Animation
• Finite Element Analysis
• Draft Analysis
• Product Cost Analysis
Background
Many existing spacers are bulky, inconvenient to carry, and highly clinical in appearance. To address this issue, I focused on designing a compact, manufacturable spacer that is travel-friendly, kid-friendly, and visually approachable while maintaining effective performance.
Inhaler spacer with face mask
Design Process
I began my design exploration by creating a mood board to define the overall tone of the product. I then explored a range of design concepts, which eventually led to the final sketch, balancing functionality, aesthetics, and manufacturability.
Mood Board
Design Exploration Sketches
Final Sketch
3D CAD Model
Flower Chamber is a stylish, manufacturable inhaler spacer designed for everyday use and effortless on-the-go convenience. The spacer combines medical effectiveness with a stylized, water-bottle-inspired design. It maintains full clinical functionality while remaining visually appealing. This discrete form allows children with respiratory conditions to carry and use the device confidently at school or while traveling.
One-Way Valve Assembly
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Prevents backflow of medication into chamber
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Installed separately
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Valve housing and retainer grid snap fit together with silicone diaphragm​ fixed in between
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Installed from either end of chamber, resting on an internal ledge to fix assembly to main body
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Valve housing
Silicone diaphragm
Retainer grid
Installed from top
Internal ledge (chamber)
Installed from bottom
Cross-Sectional Views
One-Way Valve Assembly
Permanent snap-fit
Internal ledge (main body)
Main body drafted by 2 degrees on both ends for injection molding
Chamber (Main Body) and Inhaler Adapter (Bottom)
Temporary snap fit
3D Animation
Features:
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3 primary components (mouthpiece, spacer chamber, and inhaler adapter)​
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Snap-fit and locking thread assemblies with alignment indicators
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Inhaler adapter (bottom part) has a vented grill and reinforced supports around the adapter opening
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Contains a one-way valve assembly consisting of the retainer grid, silicone diaphragm, and valve housing to prevent medication backflow, installed separately
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Removable soft TPE accessories, including protective lids and a decorative sleeve
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Note: all spacer components modeled from scratch; only external CAD file is the inhaler used for demonstration
Draft Analysis
A minimum 2-degree draft was incorporated throughout the model to ensure injection moldability.
Finite Element Analysis
FEA shows that the tip of the mouthpiece (PP) can withstand a load of 400 Newtons.
Cost of Labor, Burden, & Materials
A cost analysis of labor, burden, and materials estimates a manufacturing cost of ~$4 per unit.
PROJECT VIDEO
