Water Heater

Cascade Water Heater – Styling & Product Development

Designed & Developed by: Lemorian Experience Design

Lemorian Experience Design played a key role in the styling, engineering, and development of the Cascade Water Heater, delivering a product that successfully balances innovative design, cost-effective manufacturing, and large-scale market viability.

Design & Manufacturing Challenge

One of the primary challenges of this project was to achieve a distinctive and modern product design while avoiding conventional injection molding, which would have significantly increased tooling and production costs. The client required a solution that was both economically feasible and scalable for mass production, without compromising on aesthetics or durability.

Innovative Manufacturing Approach

To address this challenge, Lemorian strategically adopted vacuum forming technology as the core manufacturing process. This decision enabled:

• Significant reduction in tooling and development costs

• Faster time-to-market

• Flexibility in design iterations

• Efficient production of complex forms

Implementing vacuum forming for a sphere tank water heater was a notable achievement, as it demanded precise control over material thickness, form stability, and surface finish. This approach reflects Lemorian’s commitment to innovation in manufacturing-led design solutions.

Product Styling & Aesthetics

The Cascade Water Heater features a clean, contemporary form language that enhances its visual appeal while fitting seamlessly into modern Indian households. Special attention was given to:

• Proportion and surface continuity

• User-friendly interface placement

• Aesthetic differentiation in a competitive market

• Practicality for installation and maintenance

The spherical tank design not only adds a unique identity to the product but also supports structural and thermal efficiency.

Engineering & Documentation

As part of the development process, Lemorian delivered comprehensive engineering documentation, including:

• Detailed part drawings

• Mold core and cavity drawings

• Manufacturing-ready specifications

These deliverables ensured accuracy, repeatability, and efficiency during production, enabling smooth coordination between design and manufacturing teams.

Market Success

The Cascade Water Heater has achieved strong market acceptance and is currently selling across India, validating the effectiveness of the design and manufacturing strategy. Its success demonstrates how thoughtful design combined with cost-conscious engineering can result in a commercially successful consumer product.

Outcome

The Cascade Water Heater project stands as a testament to Lemorian Experience Design’s expertise in:

• Consumer product styling

• Manufacturing-driven design innovation

• Cost optimization without design compromise

• End-to-end product development

This project highlights Lemorian’s ability to transform challenges into opportunities, delivering products that are visually distinctive, production-ready, and market-proven.