Air Well
Prize(s):
WINNER 2026 PRODUCT DESIGN / Industrial Product | PRODUCT DESIGN / People-Centric Design
Lead Designer(s) Name(s):Alex Wairimu
Photo Credit:Alex Wairimu
Project Location:Leicester, United Kingdom
Design Status:Prototype
Website: View
Product Description:
Every day, millions of artisanal miners inhale deadly dust like silica and arsenic, causing irreversible lung disease among other conditions, including early death. A recent survey in Kisumu, Kenya, found over 70% of miners missed work due to dust-related injuries. Despite knowing the risks, miners remove respirators because they cause heat, suffocation, blind spots, and discomfort. Current respirators fail in real-world mines: cheek-mounted cartridges strain necks, rigid straps cause sores, and narrow visors limit vision. Additionally, costly non-modular designs necessitate full replacements, a significant burden for low-income workers. Air Well redesigns respirators around miner endurance: 1. Temple-mounted cartridges shift weight to the head’s pivot, cutting neck strain; a lightweight composite frame is 10% lighter. 2. Micro-airflow channels and multi-layer seals reduce heat and moisture while keeping airtight fit. 3. A wide, anti-fog wraparound visor offers 21–51% better peripheral vision. 4. Modular parts enable miners to replace components affordably, thereby extending product life.
Every day, millions of artisanal miners inhale deadly dust like silica and arsenic, causing irreversible lung disease among other conditions, including early death. A recent survey in Kisumu, Kenya, found over 70% of miners missed work due to dust-related injuries. Despite knowing the risks, miners remove respirators because they cause heat, suffocation, blind spots, and discomfort. Current respirators fail in real-world mines: cheek-mounted cartridges strain necks, rigid straps cause sores, and narrow visors limit vision. Additionally, costly non-modular designs necessitate full replacements, a significant burden for low-income workers. Air Well redesigns respirators around miner endurance: 1. Temple-mounted cartridges shift weight to the head’s pivot, cutting neck strain; a lightweight composite frame is 10% lighter. 2. Micro-airflow channels and multi-layer seals reduce heat and moisture while keeping airtight fit. 3. A wide, anti-fog wraparound visor offers 21–51% better peripheral vision. 4. Modular parts enable miners to replace components affordably, thereby extending product life.
Product Innovation / Specification:
Temple-Mounted Cartridge System: First respirator to shift cartridges from cheeks to temples, aligning weight with the head’s natural pivot point to reduce neck strain and fatigue during 12-hour shifts. Micro-Airpod Ventilation: Embedded micro-airpods regulate temperature and humidity in real time, cooling the facial area while maintaining filtration. Multi-Layer Dynamic Seal: Combines thermoregulation and vapor protection. Skin-contact: Medical-grade silicone. Dissipation: Aerogel mesh wicks moisture. Barrier: Fluoroelastomer blocks oils/chemicals. Materials & Dimensions: Shell: ABS (impact-resistant) Visor: 5mm polycarbonate (clear, scratch-resistant) Seal: Triple-layer (silicone/aerogel/fluoroelastomer) Straps: Nylon core with silicone cover Cartridges: Standard store-bought Top View: 305.65mm (L) × 297.91mm (W) Front View: 220.09mm (L w/ cartridges) × 203.27mm (H) User-Centric Design: Redesigned straps and cartridge placement reduce strain. Micro-airpods and multilayer seals enhance breathability. Wide visor improves visibility without breaking the seal. Certifications in progress; full drawings in Appendix.
Temple-Mounted Cartridge System: First respirator to shift cartridges from cheeks to temples, aligning weight with the head’s natural pivot point to reduce neck strain and fatigue during 12-hour shifts. Micro-Airpod Ventilation: Embedded micro-airpods regulate temperature and humidity in real time, cooling the facial area while maintaining filtration. Multi-Layer Dynamic Seal: Combines thermoregulation and vapor protection. Skin-contact: Medical-grade silicone. Dissipation: Aerogel mesh wicks moisture. Barrier: Fluoroelastomer blocks oils/chemicals. Materials & Dimensions: Shell: ABS (impact-resistant) Visor: 5mm polycarbonate (clear, scratch-resistant) Seal: Triple-layer (silicone/aerogel/fluoroelastomer) Straps: Nylon core with silicone cover Cartridges: Standard store-bought Top View: 305.65mm (L) × 297.91mm (W) Front View: 220.09mm (L w/ cartridges) × 203.27mm (H) User-Centric Design: Redesigned straps and cartridge placement reduce strain. Micro-airpods and multilayer seals enhance breathability. Wide visor improves visibility without breaking the seal. Certifications in progress; full drawings in Appendix.
Product Sustainability Approach:
Air Well integrates circular design, durability, and local reuse to extend product life and reduce waste. 1. Sustainable Materials: a. Modular ABS shell: 100% recyclable through common streams. b. Seal: Medical-grade silicone. c. Filters: Standard store-bought cartridges support bulk recycling partnerships. 2. Longevity Through Modularity a. Only worn parts—straps, filters—are replaced. b. Snap-fit design for tool-less repairs, ideal for low-resource settings. c. Prototypes withstand 3+ years of daily use in abrasive mining conditions. 3. Circular Economy, Miner-Led a. Deposit Program: Exploring store credit for returned parts (melted/reformed). 2. Recycling Literacy: Units ship with Swahili/English recycling guides to encourage participation and build awareness.
Air Well integrates circular design, durability, and local reuse to extend product life and reduce waste. 1. Sustainable Materials: a. Modular ABS shell: 100% recyclable through common streams. b. Seal: Medical-grade silicone. c. Filters: Standard store-bought cartridges support bulk recycling partnerships. 2. Longevity Through Modularity a. Only worn parts—straps, filters—are replaced. b. Snap-fit design for tool-less repairs, ideal for low-resource settings. c. Prototypes withstand 3+ years of daily use in abrasive mining conditions. 3. Circular Economy, Miner-Led a. Deposit Program: Exploring store credit for returned parts (melted/reformed). 2. Recycling Literacy: Units ship with Swahili/English recycling guides to encourage participation and build awareness.
Local and Regional Impacts of the Product:
Mining is among the deadliest jobs—quarrying alone causes 8% of global work deaths (ILO). In Kenya’s Taita Taveta County, only 28.4% of miners use safety gear (2024 survey). A 2007 Kenyan report linked injuries to poorly designed respirators. Traditional masks strain the neck, cause fatigue, and are often removed, increasing exposure to toxins. Air Well relocates cartridges to the temples to reduce strain and improve comfort. A multi-layer seal limits toxin absorption. In underground mines reaching 51–55°C, Air Well’s micro-airpods and seal help reduce heat stress. Visibility improves by over 21%, lowering accident risk.
Mining is among the deadliest jobs—quarrying alone causes 8% of global work deaths (ILO). In Kenya’s Taita Taveta County, only 28.4% of miners use safety gear (2024 survey). A 2007 Kenyan report linked injuries to poorly designed respirators. Traditional masks strain the neck, cause fatigue, and are often removed, increasing exposure to toxins. Air Well relocates cartridges to the temples to reduce strain and improve comfort. A multi-layer seal limits toxin absorption. In underground mines reaching 51–55°C, Air Well’s micro-airpods and seal help reduce heat stress. Visibility improves by over 21%, lowering accident risk.
Lead Designer(s) Name(s):Alex Wairimu
