Physical Product — Case Study

Woodshop Monitor

A real-time air quality and respiratory monitoring system for woodshop environments.

Hardware Design Embedded Systems Human Factors Physical Product

The Hidden Risks

Three main problems

Hazard 01

Wood Dust

Exposure often causes coughing, wheezing, nasal congestion, and eye/throat irritation. 6–18% of workers exposed to wood dust develop occupational asthma.

Hazard 02

Glue Fumes

Exposure to VOCs can cause headaches, dizziness, nausea, and mucosal irritation (eyes, nose, throat). Increases risks of liver and kidney toxicity.

Hazard 03

Air Particulates

Associated with chronic cough, heavy mucus production, and airway obstruction. Can cause allergic or irritant dermatitis and asthma.

Historical Context

Two centuries of respiratory risk

The concern over respiratory health in woodworking dates back more than two centuries — from early occupational cancer links to modern OSHA exposure limits.

Milestone 01

18th Century

Percivall Pott identified a link between occupational exposure and cancer. His findings inspired later research into trades like woodworking, where fine dust was found to cause nasal and lung diseases.

Milestone 02

Mid 20th Century

As industrial production and mechanization in woodworking grew, doctors began reporting chronic bronchitis, asthma, and cancer among carpenters and furniture makers.

Milestone 03

Post–World War II

The introduction of synthetic glues and polyurethane brought new risks from chemical fumes and VOCs. These pollutants caused long-term respiratory illness.

Milestone 04

Late 20th Century

Occupational safety agencies like OSHA and NIOSH established exposure limits, leading to early air-sampling and filter-based testing.

By the Numbers

3 insights of current woodworking employees

50%

Chance of asthma — workers exposed to dust are at a much higher risk of developing asthma compared to non-exposed workers.

35%

Of carpenters experienced respiratory problems (cough, wheezing, reduced lung function).

3.6M

Exposed workers — about 2% of the total workforce in the EU are estimated to be exposed to harmful levels of wood dust.

Market Audit

What's out there — and why it's not working

Existing monitoring devices are either prohibitively expensive, require medical knowledge to interpret, or simply weren't designed for the unique conditions of a woodshop.

Dylos

$465.00

Temptop

$169.99

EasyOne Air

$2,615.07

Minispir

$1,560.95

Expensive and non-durable

Requires users to understand medical terms

Feedback loop error & no data logging

Not designed for woodshop environment

User Research

What do primary users say about this?

Primary Users

Three primary users

Student Assistant

Tsunemasa Fujiwara

Wood Shop Worker — Student Assistant

Frequent User

Sean Yan

Frequent Wood Shop User — Student

Professional

Derek Brown

Professional Wood Shop Worker — Self Employed

Key Findings

Three key insights from research

Insight 01

Visibility & Awareness Are Low

Users need visual, data-driven awareness tools that make invisible dust and fumes tangible and actionable in real time.

Insight 02

Safety Habits Are Compromised

Safety systems must be frictionless — integrated into existing workflows so comfort and convenience don't override protection.

Insight 03

Accessibility & Maintenance Limit

There's a need for affordable, low-maintenance monitoring systems that suit both educational and independent workshops.

Key Pain Points

What's really going wrong

Pain Point 01

PPE Noncompliance

Students often neglect masks due to discomfort, heat, or simply forgetting.

Pain Point 02

Invisible Risks

Fine particles and VOCs are hard to perceive in the moment; irritation builds up unnoticed.

Pain Point 03

No Feedback Loop

Students have no way to connect their exposure with short-term symptoms like coughing or long-term risks like asthma. Without data, faculty cannot alert poor ventilation.

Reframing

How might we…

How Might We

How might we design a simple, real-time system that visualizes air quality and respiratory health in a way that's understandable and actionable for woodshop users?

Target Users

User personas

Empathy Mapping

Say, Do, Think, Feel

Environmental Research

Understanding the woodshop

Mission

What we're building toward

Mission Statement

Create an accessible, real-time respiratory monitoring system that increases awareness of air quality in wood shops, empowering users to work safely without disrupting their creative process.

Requirements

Must-have considerations

Real-time air quality monitoring (PM2.5 / PM10 and VOC levels)

Visual indicator or display showing air quality status clearly

Alerts (color change, buzzer, or notification) when air quality becomes unsafe

Compact and durable hardware suitable for dusty workshop environments

Basic data logging

Hygiene, repairs, reliability, durability

Privacy and cost-effectiveness

Material selection and user experience

Components

The sensor stack

Four sensors form the core of Woodshop Monitor — measuring particulate matter, VOCs, environmental conditions, and airflow pressure to give a complete picture of workshop air quality.

BME280

Environmental Sensor

Measures ambient temperature, relative humidity, and barometric pressure

PMS5003

Particulate Matter Sensor

Measures PM1.0, PM2.5, and PM10 — critical for detecting fine dust from cutting and sanding

SGP30

Gas / Air Quality Sensor

Measures TVOCs and provides eCO₂ estimate — monitoring fumes and off-gassing

MPXV7002DP

Differential Air Pressure

Measures air pressure difference between two ports — detects airflow or breathing pressure

System Flow

How it works

A four-step process designed for zero friction — students finish their woodshop session, take a quick spirometry reading, and get instant visual feedback.

Step 1

Initiation

Student finishes woodshop, goes towards the kiosk/station. Takes a sealed, single-use mouthpiece from a dispenser near the station.

Step 2

Insert & Test

Student slots the mouthpiece into the spirometer port with a simple click-in mechanism. On-screen prompt says: "Take a deep breath, then blow steadily into the mouthpiece." Device measures lung capacity and airflow within 5–10 seconds.

Step 3

Results

The screen displays results as either red, yellow, or green — Red for bad, Yellow for warning, Green for good. Simple, instant, no medical jargon.

Step 4

Disposal

Student removes the used mouthpiece and drops it into a clearly marked disposal bin. Device resets for the next user.

Visual Direction

Moodboard

Color Exploration

Color palettes & chosen direction

Color Palettes Explored

Chosen Color Palette

Initial Sketches

Thumbnail sketches

Electronics

Initial circuit testing

Physical Prototyping

Initial prototypes

Foam Prototypes

All Initial Prototypes

Validation

User testing

Development

Prototype development

Iterative refinement across venturi tube design, mesh filters, spirometer inserts, bezel development, dock form, and vent prototyping — each component tested and evolved independently before integration.

Angle Testing