DUSTI

The problem

The fashion manufacturing industry employs approximately 60 million workers worldwide, with an estimated 27 million affected by occupational health concerns. Respiratory conditions are particularly common, driven by ongoing exposure to airborne fibres, dust, and lint, released during routine fabric handling. These fine particles settle onto surfaces and disperse into the air through movement and airflow, contributing to both immediate irritation and long term respiratory risk. This exposure has direct physiological consequences. Inhalation of fibres can trigger coughing, sneezing, and throat discomfort, while prolonged exposure has been linked to chronic pulmonary dysfunction. Beyond physical symptoms, continued interaction can also lead to psychological burden as workers experience accelerated fatigue, unease, and uncertainty surrounding job sustainability and wellbeing.

Despite the prevalence of these risks, current preventative measures provide only partial relief. While personal protective equipment and ventilation systems exist, very few solutions are simultaneously ergonomic, affordable, and accessible. Consequently, protective measures are inconsistently adopted, with comfort and productivity often prioritised over safety. This gap informed the development of Dusti, a fibre management solution.

Design Intervention

Dusti is a motorised fibre collecting roller that attaches to existing, multi meter long workstations, minimising worker exposure through seamless, automatic cleaning. Once activated, it travels along low profile rails, lifting loose fibres before they can become airborne. Adjustable speed and pause controls preserve workflow efficiency, while interchangeable attachments cater to diverse materials and applications. Upon completion, Dusti returns to its casing, where water jets cleanse the roller and loosen fibres into a removable filter for disposal. Its modular design supports ergonomic use, simple part replacement, and long term durability in high activity environments.

By consolidating fibre removal, automated cleaning, and filtration into a single system, Dusti alleviates the physical demands of repetitive cleaning while reducing dependence on uncomfortable PPE and high cost units. It limits the diffusion of residual fibres, promoting safer breathing conditions throughout daily operations. From small workshops to large scale production floors, it delivers an accessible, reusable, and scalable solution. Ultimately, it allows workers to focus on their craft while the workspace maintains itself, helping to reduce both immediate irritation, long term inflammatory responses, and psychological stress associated with health concerns.

Scenario OF USE

the process

Building on my research, ideation was guided by benchmarking insights, survey feedback, and key themes identified in the problem space. Early concepts explored a range of approaches, including a rotary vacuum attachment that removed fibres at the source, an overlocker slot redesign, and a fibre collecting table roller. The table mounted roller emerged as the strongest direction as it addressed fibre buildup across large work surfaces, required minimal user effort, and integrated seamlessly into existing workflows without interrupting production. Its modular nature also allowed the system to scale across different workspace sizes and industrial contexts.

Refinement was iterative and non linear. Concepts were sketched, evaluated, and repeatedly reworked as challenges with scale, integration, and technology emerged. To better understand feasibility and usability, low fidelity prototypes using cardboard were created to visualise form, ergonomics, and movement. CAD modelling and rapid 3D printing enabled testing of moving components and tolerances, revealing issues such as insufficient clearance. This workflow allowed problems to be identified early and informed a more refined and functional direction for Dusti.

manufacturing

The exploded view highlights the key materials, colours, and finishes selected to maximise durability and usability in workshop environments. Core components, such as the motor housing, are manufactured from ABS due to its impact resistance and suitability for injection moulding. The rails are lightweight aluminium extrusions, allowing each attachment to be cut to length and customised for different workstation sizes.

A hard coated polycarbonate lid provides strength and scratch resistance while maintaining visibility of the internal mechanism. The washable rollers are formed from TPR and a silicone based gel, creating a reusable tacky surface that can be easily cleaned with warm water. Dark greys and muted tones establish a clean, professional, industrial appearance while masking dust and wear from daily use.

All components are removable, supporting straightforward part replacement and reducing both waste and maintenance costs, ensuring Dusti remains reliable in high activity production spaces and adaptable to different user needs.