Split AC

1. This is a split-type indoor unit I led the development of for a publicly listed company that was among the top three in China's air conditioning industry at the time. The unit was designed for both the domestic Chinese and North American markets, with a total mold investment of $780,000. 2. The indoor unit featured a clean, minimalist aesthetic—popular in that era—with rear air intake. Its most distinctive structural innovation was the integration of the base and the main air outlet body. In traditional AC manufacturing, these two parts are typically separate, each already highly complex in terms of mold design. Integrating them into a single part to improve production efficiency posed a significant mold engineering challenge. 3. The structural design process took over three months, including 5 rounds of design reviews and optimizations, as well as 3 rounds of rapid prototyping, testing, and iterations. Ultimately, we systematically resolved key issues such as mold feasibility, airflow performance, noise control, condensate drainage, production efficiency, assembly line layout, and UL certification—leading to a successful mass production launch.