Snoring is a widespread sleep phenomenon and a hidden enemy of health. It causes repeated sleep apnea, leading to severe hypoxia in the brain and blood. To help snorers escape this torment, VVfly embarked on developing an innovative anti-snoring device.

The challenge was clear: create a functional hardware product that effectively addresses snoring. This was not just a technical challenge but a systems engineering project requiring a perfect balance between material suitability, mechanical rationality, mold design cost, and processing convenience.

The core objective was to perfectly translate the product design into a tangible device that met all functional requirements. The key goals encompassed:

• End-to-End Product Development: Managing the entire new product development process from concept to mass production.

• Manufacturing Feasibility: Ensuring the design was optimized for cost-effective and efficient manufacturing.

• Robust Mechanical Design: Creating a structure that was durable, functional, and ergonomic.

• Supply Chain and Quality Excellence: Overseeing supplier development, mold design and production, product testing, verification, and end-to-end quality management.

The primary difficulty lay in ensuring the product adhered to its core principles of ergonomics and aesthetics while overcoming significant engineering implementation hurdles.

LKK Design assembled a cross-disciplinary team and followed a structured, phase-gate process to overcome these challenges.

 Design Research

Our team began by deeply researching the physiological mechanisms of snoring and the potential pain points of wearing a device overnight. We recognized that a successful anti-snoring device must provide a comfortable, unobtrusive experience and effective physical intervention, even while the user is asleep. These insights directly guided our subsequent design phases.

Industrial Design

In the industrial design phase, we adhered to the principle of "form follows function, and function serves the user experience." The device's form features smooth, rounded curves designed to eliminate the psychological resistance often associated with medical products. The color and material segmentation were not merely aesthetic choices but were strategically planned to define functional zones, laying a solid foundation for the CMF and structural design.

 Mechanical Structure Design – An Optimized Solution

This was the cornerstone of the project's success. To resolve the conflict between "ensuring comfort" and "providing effective support," our engineering team developed an innovative dual-material structure:

• Zonal Architecture: The housing was intelligently divided into two distinct components.

• Super-Tough Elastic Hard Plastic (Purple Part): This material forms the core support structure, ensuring the product undergoes necessary, controlled deformation to fit different facial contours while protecting the internal mechanisms.

• Soft Components (Blue Part): The areas in contact with the skin are made from a soft, comfortable material, significantly enhancing skin-friendliness and comfort to prevent irritation or pressure marks during sleep.

This ingenious design perfectly solved the engineering challenge of balancing "structural integrity and deformation" with "wearable comfort."

 Prototyping and Testing

We conducted multiple rapid prototyping iterations using 3D printing and CNC machining to validate the form, structure, and ergonomics. Following this, we proceeded to mold trials and T1 samples, rigorously testing the bonding of the dual-material structure, material formability, and assembly process. Each testing phase was aligned with the project's core objectives, ensuring the final product faithfully realized the design intent and met all functional and reliability standards.

Through close collaboration with VVfly, LKK Design delivered exceptional value:

• Functional Realization: The VVfly Anti-Snoring Device hardware prototype successfully realized all its core functions, paving the way for mass production and market launch.

• Design Fulfillment: We successfully translated a complex design based on ergonomics and aesthetics into a cost-effective, manufacturable product, overcoming the critical hurdle from design to reality.

• Supply Chain Optimization: Through early manufacturing feasibility assessments and precise mold design, we optimized the production process, controlled costs, and established a stable and reliable supply chain, providing a solid foundation for the product's market success.

The success of the VVfly Anti-Snoring Device is a testament to LKK Design's unique ability to integrate design innovation with robust supply chain management. We are not just designers; we are a trusted innovation partner, dedicated to turning great ideas into tangible, successful products.