Why is everything 38mm? I asked a Dyson engineer to explain the brand's magic number

I test vacuum cleaners for a living, so I'm very familiar with the strain that a hefty vacuum or finicky trigger can put on the hands and wrist. But Dyson is setting out to change all that with the launch of the ultra-slim PencilVac and PencilWash.

The brand's answer to this universal pain point isn't just a lighter motor — it’s a thinner grip. How thin, you may ask? The answer is always, it would seem, 38mm.

I caught up with Dyson’s Senior Design Manager, Ketan Patel, to find out more about the human-centric research behind the "Pencil" series and how a few millimeters can make the difference between a chore and a breeze.

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From hefty handle to sleek and slim

The Dyson PencilWash cleaning a floor — (Image credit: Dyson)

Dyson has come out swinging with its latest line-up of cordless innovations, the most notable of which is the striking Dyson PencilVac FluffyCones, which our Homes Editor recently reviewed.

Touted as the ‘slimmest vacuum in the world’, it has a 38mm/1.1 inch diameter handle and weighs in at just 3 pounds. I also tried the upcoming Dyson Piston Animal, which also has, you've guessed it, a 38mm diameter handle for easy handling.

And if you're wondering if the magic number stops at floorcare, you should take a look at your Dyson Airwrap, which also touts a 38mm handle.

Dyson's magic number

So why does 38mm seem to be the magic formula?

“We wanted to put all the components, such as motors, power systems, and electronics into the handle to make it feel more comfortable,” explains Patel. “And the 38mm diameter was inspired by the beauty team, when making things like the Supersonic and Airwrap hair products, and finding out how people are using the machines."

"The 38mm diameter was inspired by the beauty team, when making things like the Supersonic and Airwrap hair products"
Ketan Patel, Senior Design Manager at Dyson

“We researched anthropometric data of people's hands of different sizes — from really small hands to large — and 38mm was the diameter needed to be able to hold that machine. Above the 38mm range would become uncomfortable for people to use.”

the dyson airwrap ID in teal and terracotta colorway (patina and orange) with a lapis case, with a brush, hairfryer, curling wand attachments — (Image credit: Tom's Guide)

This should come as a breath of fresh air when compared to heavier models such as the Gen5Detect that performed brilliantly, but weighed in at a hefty 7.7 pounds.

According to Patel, design is mainly driven by convenience. Gone are the days when people would allocate a ‘cleaning’ day to vacuum their homes. Nowadays, we simply want the convenience of being able to quickly clean up messes without the hassle — especially if you have kids or pets.

“Now we don’t have a specific cleaning day; it becomes more routine,” adds Patel, “We do in much smaller bursts, and convenience becomes a big part of our cleaning habits.”

What's next?

Dyson PencilVac Fluffy — (Image credit: Dyson)

So far, we’ve seen the ‘world’s slimmest vacuum cleaner’, lighter and more robust operation, and longer-running batteries. What else can we expect to see from Dyson vacuum cleaners in the future?

“With Dyson, everything is a surprise, but we really are passionate about reinvention and solving problems that frustrate people”, adds Patel. And those solutions will make us stand above the competition.”

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As the Homes Content Editor, Cynthia Lawrence covers all things homes, interior decorating, and garden-related. She has a wealth of editorial experience testing the latest, ‘must-have’ home appliances, writing buying guides and the handy ‘how to’ features.

Her work has been published in various titles including, T3, Top Ten Reviews, Ideal Home, Real Homes, Livingetc. and House Beautiful, amongst many.

With a rather unhealthy obsession for all things homes and interiors, she also has an interior design blog for style inspiration and savvy storage solutions (get rid of that clutter!). When she’s not testing cool products, she’ll be searching online for more decor ideas to spruce up her family home or looking for a great bargain!

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