Bear Spray Redesign
Bear Spray Redesign
A vital self-defense tool, redesigned for arctic conditions.
Featuring double insulation and a handwear-friendly actuator, this design is specialized for arctic researchers and outdoor adventurers. Mockup generated by ChatGPT.
company
independent
role
researcher, product designer
user research, user-centered design, product design
skills
2 weeks
October 2025
timeline
Introduction
Bear spray is a non-lethal self defense tool designed for protection against attacking bears. It has over a 90% success rate at preventing undesirable behavior from black, brown, and polar bears (Smith et al. 2020).
A common misconception is that bear spray is not effective on polar bears due to their size, as well as the extreme conditions of the Arctic (Wilder et al. 2023). Research has demonstrated that while bear spray is effective on polar bears, climate conditions and heavy gear make bear spray difficult to deploy.
I decided to address this challenge by redesigning bear spray for arctic conditions.
Read the full report
Problem Statement
Despite the large bear population in the Arctic, many individuals do not carry bear spray because it is more difficult to carry and deploy in arctic conditions. Additionally, misconceptions about its efficacy on polar bears have discouraged some users from carrying it.
Goal
Design a specialized bear spray canister that maximizes spray range in cold conditions, and allows easy access with winter gear. Use both product design and branding design to assert bear spray’s efficacy in the Arctic.
User Research
This product would be used be individuals who spend time in the arctic wilderness, primarily outdoor athletes (snowshoers, hikers, and backpackers), and field researchers such as biologists and meteorologists. This group is typically age 20-40, with average to above average strength and agility.
Fears:
Unsafe conditions, emergency situations without access to help/resources
Equipment damage or malfunction
Loves:
Comfortable, practical equipment with minimal burden
Mobility and freedom to explore
Aspirations:
Travel, explore, engage in the wilderness without threat to safety or health
Protect and support the wilderness without harming wildlife or the ecosystem
Traits:
Reasonably cautious, alert and aware of their surroundings
Independent and bold, comfortable traveling in remote regions
Frequently wearing heavy clothes and carrying a large amount of equipment
Scholarly Articles
“An Investigation of Factors Influencing Bear Spray Performance” Smith, T., et al. (2020)
At -7°C (19°F) and below, spray plume narrows and range decreases to <6 meters (room temperature = 12 meter range) (see below)
“Efficacy of Bear Spray as a Deterrent Against Polar Bears” Wilder, J. M., et al. (2023)
Analysis of 19 documented polar bear attacks where bear spray was used, and 54 attacks where it was not used
Bear spray was effective in 18/19 incidents where it was used, and could have been effective in 50 of the 54 situations where it was not used
Left: Bear spray plume distance as a function of temperature. Lines connecting measurements are to link symbols and do not indicate measurements between (Smith et al. 2020).
Patents
US8100298B2: Unitary Aerosol Actuator
Example of a glove and mitten friendly actuator design, with a twist lock instead of the canister’s original two-piece safety mechanism.
While I ultimately decided that the twist lock would not be secure enough for a potentially harmful substance like capsaicin, the actuator’s ergonomic form inspired parts of my own actuator design.
US20230365916A1: Biodegradable Thermal Insulation Material
A biodegradable insulation material based from temperature resilient mycelium, that can be affordably manufactured in arctic regions such as Alaska.
Canister insulation would increase the spray range
Eliminate cost of importing canisters and insulation material
A sustainable material choice, since bear spray is a single-use product that must be replaced after any and every deployment
Standards
Department of Defense Design Criteria Standard 5.1.1.1.1.5 Compatibility with Handwear
This standard states that a device’s controls must be compatible with the handwear used in the anticipated environment. This standard reinforces the importance of designing a bear spray canister specialized to cold environments, with an actuator that is friendly to users wearing gloves or mittens.