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Low-impact industrial design through process simplification

Perfectly Imperfect — a cold-bent steel door handle designed to reduce complexity, material use and environmental impact.

perfectly imperfect sustainable industrial design

Industrial design

Client — Keim GmbH

Status — In production

Award — European Product Design Award

european product design award winner

Simplifying the process

Problem

How can manufacturing simplification become design quality?

The project starts from a clear question:
is it possible to reduce process, components and impact without compromising identity, ergonomics and perceived value?

The goal was not to add complexity, but to remove what is unnecessary.

Solution

Perfectly Imperfect originates from a simple gesture: a bend.

A minimal deviation that becomes structure, language and function.

The handle is developed from a cold-bent steel tube, avoiding brass casting and dedicated molds.
This approach reduces production steps, material use and energy consumption — turning the manufacturing logic into form.

Imperfection becomes a design principle.
Visually imperfect.
Structurally precise

Result

An essential, industrially viable and recognizable product.

A project that combines industrial design, process simplification and sustainability into a single solution — awarded internationally and brought to market.

Hand-drawn sketch of a cold-bent steel door handle concept
Minimal steel door handle installed on a door
Designer Francesco Sommacal holding and testing a cold-bent door handle prototype
Exploded view of steel door handle components
Close-up of the bent steel tube forming the door handle

From imperfection to system

The bending point is not an aesthetic detail, but the core of the project.

From this controlled anomaly emerges a coherent system of proportions, ergonomics and components — where form and production coincide.

Simplification does not reduce the product.
It defines its character.

Door handle designed by Francesco Sommacal, industrial designer

Project insights

Perfectly Imperfect is a sustainable industrial design project exploring the relationship between form, production process and impact reduction.

The concept is based on a simple logic: simplify the process to improve the product.
Instead of relying on traditional casting and tooling, the project uses cold mechanical bending of steel as its core principle.

This choice reduces components, production time and material consumption.

CO₂ reduction

Sustainability is not treated as an added feature, but as a direct consequence of the design.

Fewer production steps mean less energy, lower complexity and a potential reduction of the CO₂ footprint.

The role of design

At the same time, this approach generates a recognizable form where apparent imperfection becomes identity.

The project operates between rigidity and lightness: steel — typically perceived as rigid — is reinterpreted through a gesture similar to a natural flex.

This contrast defines both the visual character and the ergonomic quality of the object.

Added value

Perfectly Imperfect represents an approach to product design based on intelligent simplification:

reducing without losing quality,
simplifying without weakening the project. A case where innovation, industrial logic and essential design align

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