Kaloud Lotus 3 Product Design

Kaloud, one of the leading companies in the hookah universe, was founded by Reza Bavar in 2011. Kaloud’s vision is to innovate and revolutionize the hookah space. Inspired by a timeless tradition, they dedicated themselves to offer a unique experience between families, friends, and new acquaintances while applying modern technological methods. 

We worked with Kaloud to design a new version of this HMD product, while resolving issues the previous versions had and implementing upgrades in function and aesthetics. This is how this journey began and resulted in launching the new and improved HMD, the Kaloud Lotus 3.

The Kaloud Lotus 3

The Lotus 3, one of the newest products in the Kaloud product line, is a heat management device(HMD) that combines the best features of the previous models. The Lotus 3 was designed with the user in mind, to make the hookah smoking experience more enjoyable, producing better clouds, fuller taste, while using less tobacco and burning the charcoal more efficiently which makes the hookah session last 50% more time than its predecessors.

The Lotus 3 is available in two variations, stainless steel and aluminum. It features a beautiful flowery design with air flow control, that allows the users to control the heat, the smoke output and ensures that the charcoal lasts longer, due to improved functionality.  This new design is a jewel that will decorate your space.

The Kaloud Lotus 3’s Story

Since we started working with Kaloud on their third generation of hookah products, we knew that we had to create something special, not only for them but also for the hookah community. We took on the challenge and started our research by immersing ourselves in the hookah world, understanding the culture and the smoking rituals. 

As our journey began, we had to map out the entire engineering process to create a well-thought design. 

The New Product Development Process(NPD) requires several steps we expand on below which include Product Design, Product Engineering, Simulation and Prototyping.

Product Design

Concept Brainstorming & Sketching

The ideation process is always very important to come up with the right design direction. As part of Kaloud’s team, we started brainstorming by looking at the current product line and understanding what could be improved. We also looked at competitors’ products on the market and researched the latest hookah trends.

We started by sketching different concepts based on our research and understanding of the heat management devices (HMD). From there, we sketched out several concepts for the Lotus 3.

After several rounds of brainstorming and sketching , we had a good understanding of what needed to be improved and how engineering certain aspects could make this an innovation. The notes of this brainstorm process guide the development. The early sketches are the aesthetic foundation that then moves into a concept design, while the functional upgrades tie with the product engineering part of the process.

Industrial Product Design

Once the sketch was ready, we had to go through the concept generation phase. A phase that was essential to ensure that the aesthetic design intent is conveyed into the outline of the product’s shape in the early 3D model .

This is the stage where we focused on the details and aesthetics of the lotus 3.

3D CAD Design and Modeling

After several iterations, we arrived at the final concept design of this HMD that was translated into a 3D model via 3D CAD(Computer Aided Design).  Then this 3D Model passed on to the engineering team to add all the functional details in the Engineering CAD and Mechanical design phase.

Product Rendering

After the concept design was ready, we had to create visual representations of the product. This is where 3D product rendering comes in handy as it allows us to create photo-realistic images of the product that can give us an idea of what it can look like eventually and make early changes to the concepts. We used 3D rendering to create different images of the Kaloud Lotus 3 from different angles. 

After the final design is finished, photorealistic product renders may allow a brand to use these images to market and promote a product before it is even manufactured.

Product Engineering Services

Engineering Computer Aided Design (CAD) & Mechanical Design

The next step of our product engineering service was to create a 3D model of the Lotus 3. 

As part of Kaloud’s team, we used CAD software to create a detailed 3D model of the Lotus 3, implement the mechanical design and details, while taking into account all the design aspects and requirements. During the product engineering phase , we had to come up with solutions regarding the function of the product, apply DFMA principles and select materials.

Material selection

Material selection is an important part of the phase that defines all the materials of the product parts. We needed to define this in this phase and plan the manufacturing techniques that would be used. Each manufacturing technique requires specific guidelines to ensure the product can be manufactured without issues. 

We decided that that product would be manufactured in Aluminum and Stainless Steel versions while a few parts had to be made of silicone. Selecting the right materials relies on addressing the right requirements, in this case Durability, Heat Capacity, Thermal Expansion, Thermal Conductivity and Thermal Stress were of utmost importance as this product would be heated in very high temperatures. The selection of these materials also favors aesthetics as there are many options for finishes that convey a more premium look and feel at the product.

Design for Manufacturing & Assembly

DFMA (design for manufacturing and assembly) is the process we follow to highlight any potential issues that could occur during the manufacturing process and address them before moving to the next stage.

Product Documentation - Technical Drawings

In order to convey all the details of a product’s shape, form, function, product documentation is essential for production of prototypes or full manufacturing.  We prepared all the manufacturing 2D drawings needed for production along with the 3D step files(or other formats), Bill of Materials(BOM) files and assembly sequence manuals  that fully defined the product’s final shape, dimensions, function, materials, finishes, and ensured that the prototypers and manufacturing agents had limited room for change.


Once we had a final engineered CAD model ready, it was time to move to the prototyping stage. This is where we took the 3D design of the heat management device and turned it into a physical representation of the product that could be tested.

This is where our knowledge and prototyping capabilities with 3D printing technologies came in handy. We used these technologies to create prototypes that we would use to test the product before moving to the manufacturing stage.

FDM-FFF 3D Printing

We used FDM-FFF 3D Printing to make an early prototype of the Lotus 3 that was meant to help us evaluate the feel, appearance and function. 

With our prototyping service, we were eligible to test the product to make sure it meets the requirements set by the client. This allowed us to find any potential issues and address them before moving to the next stage. Usually at this stage we find small details that need to be revised and modify the 3D CAD model of the product. This was the case for this one as well. 

SLA-DLP 3D Printing

On the next prototyping round we used SLA-DLP 3D Printing to get an even more accurate model and evaluate fit and function further in detail. 

This confirmed the product was ready for a sample prototype that uses the same materials as the final product and in this case CNC machining for the parts in aluminum and stainless steel. 

The final sample was a step before production and represented the final product as close as possible. This allowed Kaloud to test the sample in the exact use the product is meant for and confirm it is ready for production.

Final design edits

After getting feedback from the sample prototype we modified the last details needed to optimize the product and ensure it is ready for production.

Once Kaloud was satisfied with the new engineered lotus model and the documentation files, the project was almost completed. The only thing left was to manufacture and package the product, and ship it to the customers.

Since then, we continued to work with Kaloud on other projects and products, providing our product engineering and design expertise to help them bring their products to life.

entered the market in November 2021​

As for the Kaloud Lotus 3, its story continues as it entered the market in November 2021 and delighted hookah enthusiasts around the world, who now enjoy a better smoking experience. The product is available for purchase on Kaloud’s website. 

The product was so successful that it was submitted in several Design Awards in the product design category, while we are still awaiting the results.

Design Tools & Methods Used

In this project, we used the following tools and methods:

Tools: Solidworks, Autodesk Inventor, Autodesk Inventor Nastran, Keyshot, 

Key Skills and Processes include: 

  • Expertise in Product design
  • Expertise in Product engineering
  • Expertise in Computer Aided Design (3D CAD Modeling)
  • Design for Manufacturing (DFM) 
  • Design for Assembly (DFA) 
  • Technical Drawings for Manufacturing
  • GD&T knowledge 
  • Tolerance Analyses 
  • Stress Analyses 
  • Knowledge of manufacturing processes and design guidelines for each
  • Prototyping and 3D Printing via FDM/FFF and SLA/DLP

Are you looking to bring a product idea to life?

Looking to create a similar product? Do you want to improve and optimize your next product generation?  Do you have an innovative idea, or a hand sketch of a product idea that you want to bring to life? Our team of engineers and designers can help. We have the expertise and experience to turn your idea into a real, tangible product.

Scroll to Top