Engineering for the Field: How FAMCO’s Redesigned Flush Wall Vent Puts Contractors First
FAMCO Engineer, Alex Herrington
At FAMCO, we believe innovation doesn’t stop at the shop floor. Our commitment to continuous improvement drives us to elevate not only our manufacturing systems but also the real-world utility of every product we create. A recent milestone in this journey is the comprehensive redesign of our flush wall vent, a breakthrough shaped by contractor insights and engineered with precision to deliver next-level performance on the job site.
Our team received recurring feedback for improvement with this product, which soon caught the attention of our product development team. One key member of the team was Alex Herrington, Lead Engineer, who was responsible for the redesign of the Flush Wall Vent from ideation through implementation.
The new flush wall vent differs notably from its predecessor and not just in appearance. Designed with the user in mind, the new version features:
A One-Piece Damper: Previously composed of four parts, the damper has been streamlined into a single, reliable piece. This reduces mechanical failure points and enhances long-term durability.
Hidden Drill Holes: By repositioning the drill holes beneath the damper, installation is cleaner and better protected from the elements.
Improved Drip Edge: The top-mounted drip edge now fits snugly without tilting back toward the wall, addressing a frequent pain point reported from the field.
Screen Attachment and Paint Options: A reimagined screen mounting method has unlocked the ability to offer painted versions, providing both functional and aesthetic flexibility.
Potential Magnetic Closure: Introducing a magnet assists in damper control, preventing disruptive damper noise when the vent is not in use.
Optional Short Tube: We added an optional 2” low profile short tube on the back for easy connections to ducting.
One of the key project objectives was achieving market-leading value. By closely collaborating with contractors, Alex carefully evaluated which features provided tangible benefits versus those that unnecessarily drove up cost. This approach revealed that many competing products were over-engineered for such a straightforward application.
The design process was not without its challenges. Engineering a functional one-piece damper was a significant hurdle, requiring at least a dozen iterations. But for Alex, this problem-solving journey was the most fulfilling part of the process.
“It’s the first time we’ve ever done a one-piece damper at FAMCO,” he explained. “But now that we’ve proven it can work, we’re looking at applying this concept to more products across our lineup.”
At FAMCO, continuous improvement isn’t just a slogan, it’s a strategic priority. Every product refinement is a chance to better align with customer needs, reduce manufacturing overhead, and unlock superior value for our partners in the field.
As Alex puts it, “We always look for opportunities to improve our quality. That’s what this project was all about engineering a better solution for a real-world application.”
With the redesigned flush wall vent setting a new standard, the engineering team is already looking to what’s next. Future initiatives include broadening filter rack options to suit a diverse array of air handlers and expanding the one-piece damper innovation across additional product lines.
Our commitment to continuous improvement is a commitment to the contractor. No product is perfect, and we are willing to innovate a solution that works best for you. That’s why we are the contractors’ first choice.
