EXO

In a team of three, I was tasked with redesigning the current USPS mail-carrying bag to incorporate a harness and reduce strain on couriers.

Our solution: a lightweight harness with a durable HDPE exoskeleton to distribute weight, a modular attachment system for new modular packs, and customizable sizing and connection points for the main bag.

Reducing strain, increasing balance, and allowing for more customization in positioning and organization. 

Duration
7 weeks
April–May 2024

Tools
Softgoods
Tech Pack Creation
User Research

Team
Ethan Del Rosario
Maya Dolan

WHY REDESIGN? 

 
USPS mailbags have not changed significantly since they switched from leather to canvas in the 1970s.

We interveiwed a local mailman and learned three main pain points (elaborated on the right): Weight strain, awkward movement, and cumbersome size. 

He often resorted to carrying the mail in his arms because retrieving it from the bag was too difficult, and commented on the lack of interior organization and customizability. Every route is different, and his coworkers all had different opinions on the best way to carry their mail.

IDEATION

In initial sketches, addressed our interviewee’s pain points by creating modular, reachable packs to replace the need for carrying the mail by hand, new ways of distributing weight to lower strain on the shoulder and knees, and multiple attachment points to allow for customization and the diverse needs of couriers.

PAPER PROTOTYPING

Two drafts of paper prototypes, first one solo (left) and later one with the team (right). Led to many of the details on the final design.

INSERT SKETCH HERE

MORE SKETCHING + 3D PRINT

Went back to sketching to figure out a flower-inspired design that was more geometric and aesthetically pleasing, and tested out several different “petal” shapes and sizes.

We then 3D printed a model that could be separated and have petals move to test out the user interactions and ensure sizing was appropriate.

UI

Because Flori is all about connection, a good app is necessary to facilitate that connection.

We wanted to include te ability to control the volume, color, and brightness, or relinquish control and allow your movements to control everything.

There is also the ability to connect with friends, start a party, view your dance history, and more.