engineering innovation for powered haircare accessories
Services
- Design engineering
- Simulation and analysis
- Manufacturing support
- Ergonomic design
- Performance testing
- Rapid prototyping
- 3D modelling
- Hardware Optimisation
- Functional prototyping
Sector
- consumer
Client
Helping shape the FlexStyle™ haircare range - from early concepts to production, with a focus on mechanical design and accessory integration.
Shark entered the haircare category with an ambitious new styling system: compact, multi-functional, and built around an innovative rotating hinge. OPD were brought in after the initial ID phase to support the development of producing a working product - solving technical challenges, helping define the architecture, and guiding accessory development.
From the core hinge mechanism to powered accessories like heated brushes and straighteners, we provided targeted sprints and engineering support across multiple generations of the product. The goal: deliver robust, intuitive products with high perceived quality under rapid timelines.
We ran short, focused sprints across mechanical design, architecture, DFM and CFD - tailored to Shark’s fast development cycles. Our work covered concept ideation, prototyping, design reviews, and problem-solving on core components like the hinge and accessory interface.
We used tools including CFD to explore airflow dynamics (e.g. Coanda effect), tolerance analysis to ensure manufacturing reliability, using rapid iteration cycles to meet tight production demands. All work was grounded in fast, collaborative feedback loops - ensuring we always focused effort where it delivered value and worked as a natural extension of the clients internal team.
With OPD’s support, Shark launched the FlexStyle™ and its follow-on products at pace. The core hinge - engineered for reliability and ease of use - has become a signature feature, while powered accessories elevated the experience.
Our flexible support model helped Shark iterate rapidly while ensuring robust engineering outcomes. The result: a successful entry into a new product category, now expanding globally through new formats and accessories.
Long-term collaboration and derivatives
OPD has supported Shark in the haircare space since 2021, contributing to key developments from the original FlexStyle™ to derivatives such as Glam and SpeedStyle. Our continued involvement reflects trust in our technical expertise and ability to deliver under pressure.
This kind of project is exactly where OPD thrives - complex mechanics, rapid timelines, and a client willing to push boundaries. From the hinge to powered accessories, we focused on creating smart, reliable solutions that could scale quickly.
