Pillow Pal

Designed with JDID for a start-up client

The idea was simple: Keep your throw pillows up off the ground and easy to access (when not in use).

Client Mock-up

The client had done some exploration of their own to see if they wanted to go forward with seeking ID support. What they brought us was a PVC prototype with which we could experiment.

Concept Exploration

Our client gave us a list of objectives to consider through the design process:

Sturdy (…enough to hold at least four large pillows.)
Slides easily under a mattress (…enough for one person to operate)
Minimal unique parts
Ships small (…enough to fit in a Smart ForTwo)

Bonus: Potential to be modular (…for twin through king size mattresses)

Through Lego models and sketches I eventually devised a system that would allow all four panels of the fence (flip up portion) to move simultaneously. This was achieved by using a D-shaft and clocked channels that could be molded with a top/ bottom mold approach.

Prototype 1

A 3D print was going to take too long and cost too much this early into development. We proposed laser cut acrylic components.

We knew that friction between the mattress and box spring would be our greatest obstacle. Our first pass at a prototype showed us just how difficult it would be to overcome.

Prototype 2a & 2b

More attempts were made to reduce friction, but there was always a snag.

2A: We created a tapered I-beam to be strong while reducing surface area.

2B: We tried the same tapered tube approach as the client mock-up

Neither of these proved successful.

Functional Prototype

We concluded that the best test would be to create a prototype as close to DFM spec as possible. Through surface finish and rib spacing (underside) modifications we were able to greatly reduce friction.

We achieved the goal of reducing the unique parts to a low number: Six.

Top and bottom views of the components in packaged layout. (Easily small enough to fit in a Smart fortwo.)