Industrial - Bachelor

AERO CHARGE

Tackling heat stress in the trades with a practical, wearable cooling system. The compact fan clips to the waist or collar and automatically adjusts airflow based on activity. Using interchangeable tool-brand battery inserts, it provides targeted cooling when workers need it most, without restricting movement or workflow.

Andy Nguyen

THE PROBLEM

Tradespeople face physically demanding work in environments that often expose them to extreme heat, whether outdoors under the sun or inside poorly ventilated spaces. Prolonged exposure to high temperatures can lead to heat stress, causing fatigue, dehydration, reduced focus, and increased risk of accidents.

These conditions negatively impact both worker safety and productivity, yet current solutions are limited, often impractical, or fail to integrate seamlessly into everyday workflows. Traditional cooling methods, such as hydration breaks or loose clothing, provide some relief but do not address the constant thermal load experienced during active work.

Tradespeople need a solution that can actively regulate body temperature without restricting movement or interfering with their tools and tasks. By understanding the real-world conditions of jobsites, this project identifies the critical need for a personal, wearable cooling system that is durable, easy to use, and adaptable to the tools and routines tradespeople rely on every day.

Protection of workers from extreme heat is not just a health imperative but an economic necessity.

world health oraganisation (2025)

Key findings from surveys and interviews identified:

– Workers regularly experience heat fatigue, sweat build-up, and discomfort during physically intensive tasks
– Existing cooling solutions are bulky, impractical, or not suitable for trade environments
– Extra devices are often seen as inconvenient or unnecessary unless they offer real, hands-free benefit
– Safety and productivity drop when heat levels rise, but workers often “push through” rather than stop to cool down

Key usability issues observed during on-site and workshop research:

– Cooling products often interfere with PPE (tool belts, harnesses, ear protection, high-vis, etc.)
– Common neck or handheld fans are not secure enough for active tasks and aren’t suitable while operating tools
– No universal power solution devices required separate chargers instead of using existing tool batteries
– Current solutions are not durable enough for worksite conditions (dust, knocks, sweat, long hours)

The Research report

Name
Heat Stress Research Report
File Type
application
File Size
3 MB
Download File

How it works

The wearable cooling system operates by delivering targeted airflow to the body while adapting to the user’s activity level. The compact fan clips either to the waist or collar, keeping hands free for work, and draws power from tool-brand batteries, allowing workers to use batteries they already own.

An integrated motion sensors monitor tracks the wearer’s activity, automatically adjusting fan speed to provide optimal cooling without manual input. The lightweight housing directs airflow efficiently to the upper body, helping regulate core temperature during physically demanding tasks. When activity increases, the system boosts airflow, while lower-intensity periods trigger quieter, low-power operation to conserve energy. The battery dock allows easy charging and swapping of batteries between shifts, ensuring continuous use on long job sites. Designed for durability and simplicity, the system balances comfort, safety, and practicality, giving tradespeople consistent, hands-free cooling throughout their workday.

Ergonomics & Functionality

Hands Free Operation
– Auto Variable Speed – adapts to user workload
– Dual Slots: two fans to charge simultaneously or be swapped easily.
– Clip-On Neck Option: Fan can attach directly to the collar for targeted cooling of the neck and upper neck, giving flexibility in how workers use the system.

Low Profile Form:
– Maximum thickness of 43mm – allows bending, kneeling, and overhead work without obstruction.
– Cable-free and balanced – eliminates snag risk

Soft Overmoulded TPU Grip Zones:
– Prevent slipping, improve handling, and absorb accidental impact.

Aero charge in use context

exploded view

Design Development Record

Name
Andy Nguyen DDR
File Type
application
File Size
5 MB
Download File

Andy Nguyen

Andy is a fourth-year Industrial Design student at QUT. He has developed skills in CAD, visualisation and creative problem-solving, and is particularly interested in manufacturing, product development and the process of turning ideas into functional, user-centred solutions.