Background
Made in collaboration with Makeshop, we were asked to create two recycling bins for vape devices - one for home or office use, and one designed for the car.
This project supported a nationwide initiative to encourage vape users to recycle their used pods, pens, and disposable devices. The recycling partners could process a large proportion of the components, but uptake from users was still low. Our role was to design an accessible product that could help close that gap.
Introducing AI to the Early Concept Stage
The project began in July 2022, right when OpenAI released DALL-E 2. AI image generation had entered the public conversation, but most people hadn’t used it yet. Before DALL-E 2, the most capable publicly available generator was DALL-E 1 - tools like Midjourney and Stable Diffusion had not launched publicly.
The leap from DALL-E 1 to DALL-E 2 was significant - it pushed AI image generation from novelty to a genuinely useful design tool.
We saw AI as a great way to make our proposal document punchy and engaging. We used DALL-E 2 to generate a cover page image created from a vague description:
With a few adjustments, we dropped this into the cover page and sent the proposal.
The response from the client went something like: "Everyone in the office really likes the concept on the front cover - can we skip the research and concept development phases in the quote and just develop this one?"
At the time, this seemed like a good idea to bring costs down, so we pressed on.
From AI Concept to Physical Prototype
We reverse-engineered the AI-generated image into workable 3D forms. Naturally, the image had no engineering intent - no wall thicknesses, no assembly strategy, and no way of actually functioning as a recycling bin. So while the aesthetic starting point came from AI, the mechanical and usability considerations still required design effort.
We went through several rounds of 3D printing, refining the proportions and internal structure to create a functional prototype. Once approved, the client passed the design to one of their offshore manufacturing partners to take to production. About a year later, we spotted the finished products in a storefront window.
What Happened in Manufacture
At first glance, the products looked great - the anodised aluminium finish matched the intent, and the overall form closely resembled the original concept.
On closer inspection, however, some issues suggested that the plastic components hadn’t gone through the usual refinement for injection moulding. The wall thicknesses and structural features were still tuned for 3D printing, which led to warping and fit issues. The internal bag-holding structure was overly thick and rubbed against the outer container.
These aren’t unusual challenges in product development, but they’re normally resolved during the engineering and prototyping stages.
Reflections - The Role of AI in the Process
In this case, the early excitement generated by the AI image unintentionally set the tone for the whole project. Because the initial concept felt so clear and compelling, the client chose to skip the foundational research and development steps. While this reduced early cost, it removed the opportunity to validate the concept properly before heading to manufacture.
AI tools have become even more powerful in the years since. It has transitioned now to potential clients bringing their own AI-generated concepts to us. It's becoming an invaluable tool for entrepreneurs and other non-designers to develop their ideas before engaging the designers/engineers.
However, AI can also create a false sense of readiness. A compelling image does not automatically translate into a functional, manufacturable product. The design process still matters - especially when committing to tooling or large production runs.
Final Thoughts
AI tools are transforming how people explore and communicate product ideas. They’re powerful, inspiring, and increasingly accessible - but they don’t replace the structured process needed to turn an idea into a refined, manufacturable product.
If you're developing a consumer product, an electronics enclosure, or any design that needs to scale from prototype to production, I can help. I guide clients through the full process - from early concept validation through to detailed engineering - and can connect you with reliable NZ manufacturers when needed.
If you'd like help with your project, reach out and let's discuss your idea. maxbetteridgedesign.com