2020
+39 3278179375 alessio.pilo.design@gmail.com
WORKING EXPERIENCES Born on April 11th, 1995 Living in Milan Product & Engineering Designer from Politecnico di Milano
ABOUT ME I'm determined and curious. The urge to reinvent myself makes me confront me with unpublished experiences. My soft skills: Lateral thinker Common sense applyer Resources manager Adaptable to circumstances Team worker Project constraints optimizer
SOFTWARE PTC Creo Solidworks Rhinoceros Autodesk Inventor Simulia Abaqus Cambridge Engineering Selector Keyshot Microsoft OďŹƒce Suite SimaPro Adobe Illustrator Adobe InDesign Adobe Photoshop Adobe Lightroom
February 2019 - April 2020: Design & Engineering internship in Cefriel, during which I took part in the development of several products, from the concept to the production and techincal aspects. University collaborations Collaboration and product development with Demco Design, Seletti, PandaBike, Kia Motors, Kone, AEG, Kyosho,Enovia and Roncato Valigie during Design courses in Politecnico di Milano. Exibition set up Collaboration in exibition set up with Demco Design for the 2016 edition of Milano Design Week. Collaboration in exibition set up with Archivio Storico Giovanni Sacchi (a Design museum) and design of expositors for this space applying the rules of Design for All.
EDUCATION Master’s Degree in Design & Engineering (2017-2019) at Politecnico di Milano (mark: 110 magna cum laude) BA in Product Design (graduated in a.a. 2016/2017) at Politecnico di Milano
LANGUAGES Italian - mothertongue English - C1 (Toeic: 870 pts in 2017)
Index
01
02
03
Guide robot Jape
Water purifier Justpure
Juice extractor Weasy
04
05
RC 1:8 nitro car Ferrari 330 P4
Baby stroller Easy one
06
07
Table lamp Orchidea
Cargo bike Allen
02
08
09
Bike locker Bullock vacuum locker
Countertop washbasin Crystal cristalplant
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11
Outdoor seat Leaf
3D modeling AEG Liliput
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13
3D modeling Lego Superbolide
FEM analysis Cheetah Xtreme prosthetic leg
03
01
Guide robot for blind Jape
2018 - Design course in Politecnico Team work of 2 people Jape is a guide robot for visually impaierd people. It’s designed to give freedom and autonomy to blind people, by guiding and avoiding obstacles, even the one that the guide stick or the guide dog can’t recognize, like high obstacles or moving ones. The dog and the stick are the two tools already used by visually impaired people, but they’re not enough, because they can’t say to the people where to go to reach a specific place, so the user can just reach places that he already know how to reach. Jape is the answer to this problem, giving safety and autonomy.
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Aim Give safety and autonomy to visually impaired people, in a non-segregating way. Target The object is made for visually impaired people of all ages. It’s small and light, and the parts that interact with the user are adjustable. Main features Laser sensors, GPS and motorized wheels provide Jape to be the perfect guide for visually impaired people. The handle has a junction that helps to undestand movements.
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Fixed handle
Upper rubber cover
Upper shell sub-assembly
Frame sub-assembly
Lower shell sub-assembly
Rear omni-wheel
Lower rubber cover
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Technologies for low batch sizes A very specific object like this has a low batch size. In our case it was 1000 units. To maintain the price low, we decided to design for technologies of production with low assestment costs. The shells are made of vacuum forming, and then machined to make the holes and the openings. The frame and the sub-frame are designed to be welded in an easy way. They are made of standard sections extruded components and they’re respectively realized with 3105 aluminium
Jape - Guide robot - 2018
alloy and AISI 304 galvanized steel.
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Lightweight to be easy to use
Jape is an object that has to be used in the city in everyday life, so it can’t be difficult to use. To ease the use, our design challenge was to make it lightweight and to have the smaller dimensions allowable from the technology inside. Its weight is 11,4 Kg. If there are stairs, the user can pull the objet from the fixed handle on the top and extract the long handle to
350 mm
use it as guide stick, since it’s telescopic.
420 mm
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Advanced technology in a small space The frame is the component on which all the technology is fixed. On the bottom there are the wheels and the batteries, then there are the wheel boards, that control the movement, and the motherboard with the GPS system and the system that operate the lasers and the cameras.
Jape - Guide robot - 2018
On the top of the frame there is a sub.frame, that permits the connection of the handles to the frame.
Sub-frame
Laser sensors
Electronics
Frame
Front motorized wheels
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02
Domestic water purifier Justpure
2019 - Design & Engineering Thesis Individual work Justpure is a domestic water purifier which combines a germicidal lamp with micrometric filtration to eliminate both dirt and bacteria from water. The main themes that guided the project were the search for a simplified interaction, the immediacy of the purification process, the low cost of replacing filters and the simplicity of maintenance.
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Aim Purify water both from inorganic and organic pollution through an UV-C filter and a micrometric one. Target The object is a domestic appliance that aim to become the only domestic water supplier. Main features Possibility to purify water with a very low filter cost and with very low and easy maintenance.
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The filling of the bottle The circular base that houses the bottle is mounted on four springs. Pushing down the bottle, the base is lowered by 2 mm, necessary to activate the switch below which starts the dispensing. When the support base is lowered, the delivery tube fixed to the body ends up interfering with the valve in the bottom of the bottle, opening it, allowing the passage of water.
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An optimized layout
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justpure - Water Purifier - Design & Engineerign Thesis - 2019
The structure of the object is developed on two volumes, a base that houses the bottle and its dispenser, and a decentralized tower that contains the filtration system and electronics. The 2-liter bottle is positioned laterally to the tower and not below it to minimize the overall height of the system, to prevent interaction from becoming uncomfortable under shelves.
Integration and robustness To limit the cost of the device, shells have been optimized. They have features of stiffening, centering and maintenance of the components, avoiding however moving parts in the molds. Where possible, various fasteners have been integrated together to minimize the number of shells.
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justpure - Water Purifier - Design & Engineerign Thesis - 2019
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The internal structure The frame contains all the technical elements. From the main solenoid valve, at the bottom, the tube branching towards the base of the micrometric filter branches off, crosses it and then descends to the base of the UV filter. Also crossed, the tube proceeds to the second valve, two-way, and branches off into the two dispensers.
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Simplicity of assembly
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justpure - Water Purifier - Design & Engineerign Thesis - 2019
The structure of the object and the division of the shells have been designed to simplify assembly and give back a sufficient resistance. Everything takes shape around a sturdy stainless steel bearing frame, to which all internal components and bodies are connected.
justpure - Water Purifier - Design & Engineerign Thesis - 2019
03
Juice extractor Weasy
2018 - Design course in Politecnico Team work of 4 people Weasy is a slow juicer that is able to divide the fruit pulp from the juice. Compared to traditional juicers, it is more integrated and has a more linear shape. This is made possible due to different tecnhical solutions: for example the cooling fan is placed in the bottom instead of in the side of the object, and it permits to avoid discontinuity in the overall shape. The placement of the components permits to limit the dimensions and integrate the waste container, which completes the shape. To make it user-friendly, are been used textures where is necessary to act.
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Aim Develop a domestic appliances with a unique shape, easy to use and user-friendly. Target The object is made for a domestic use. The form make it possible to place even in kitchen’s islands. Main features Integration of the waste container to optimize the dimensions and make a 360° good looking form. Integrated cutting grd to speed up the process.
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An innovative structure that makes the difference
The support for the motor is also the housing for the motherboard. Moreover it directs the flux of air to cool the system. This component is the heart of the object, because it permits a way to assemble that gives the possibility to save a lot of space.
Engine
Support for the motor
Motherboard
Cooling fan
Main base
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Simple use and washing phase
Weasy - Juice extractor - 2018
The main focus of Weasy is the ease of use and the speed of the process. The object contains a grid inside to cut the fruit in small pieces, avoiding the manual pre-cutting and making this phase faster. A system of metal pins allows the working of the object just when all the pieces are in place. Weasy has also an auto-cleaning system.
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Photo of 3D printed prototype
Weasy - Juice extractor - 2018
04
RC 1:8 road car Ferrari 330 P4
2018 - Parametric modeling exercise - PTC Creo Individual work The RC model of the Ferrari 330 P4 is based on the 1:8 scale Kyosho RC road frame. In this paramentric modeling excercise the professor gave the mechanical components and asked to design from zero a frame, a body and some wheels to realize the RC version of an existing car. Everything had to be realizable, so the components had to perfectly fit in the new frame. The shell is designed to be realized by vacuum forming. The wheels are designed to be realized by injection molding.
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Aim Realize an RC car with the shape of a vintage icon of motor racing. Target RC enthusiast but also collectors that usually add to their collections just static models of cars with important histories. Main features It’s a fast Kyosho RC car with a frame that adopts the proportions of the inconic Ferrari 330 P4. The proportions are also respected in the wheels and in the body.
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Managing the complexity The car is made of more than 180 pieces that interact between them in complicated ways. The elements that compose the frame are realized by using solid parametric modeling. The
shell
is
realized
through
surface
modeling, because of the high complexity of the organic shape.
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Ferrari 330 P4 - RC 1:8 scale car - Kyosho - 2018
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Ferrari 330 P4 - RC 1:8 scale car - Kyosho - 2018
05
Baby stroller Easy one
2018 - Contest for Chicco Team work of 3 people Easy One is a stroller designed to be comfortable in any circumstance, that can be adapted to the growing of the child. This is made possible by the sitting that can have three different configurations: relaxed, semi-seated and sitting. The egg is in fact made up of two main plastic bodies, and the back is adjustable in three positions. Frame and egg are bounded by a joint that has a form of a star, which allows the parent to place the egg with the desired inclination.
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Aim Develop an adaptable solution that can accompany the child in growth. Target Young families with newborn babies. The product is made for babies from 0 to 36 months. Main features Possibility to use with three different configurations. Lightweight and easily foldable frame to take up little space.
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Space for comfort The pedal board and the final part of the seat, that is adjustable, allow to use the product also as a stroller, up to 36 months of the child. So the object can accompany babies in the growht, evolving with them.
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Easy One - Baby stroller - Chicco contest - 2018
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Adaptable and light frame The frame consists of a structure in aluminum that gives it lightness, easy handling and ease of transport. It closes on itself, to occupy the minor space possible. The four wheels are all independent and can be locked in position depending on the configuration of use. The rear wheels are equipped with brakes that can simply be actuated by pushing a pedal.
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Easy detachment The object permits to adjust the position of the backrest relatively to the seat. The bumper bar, directly attached to the egg, has three positions and can be used for transport by hand. In car seat configuration, the ISOFIX attacks allow it to be anchored in the car.
Easy One - Baby stroller - Chicco contest - 2018
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Easy One - Baby stroller - Chicco contest - 2018
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06
Table lamp Orchidea
2017 - Personal project Individual work Orchidea is a table lamp that emits a diffused ambient light with low light intensity. The main component is the diffuser, which becomes the support element. The diffuser is locked between the ring nut of the brass lampholder, which has an external thread, and the lamp itself. This solution permits to use Orchidea also for suspension, by wrapping the cable on any support, so as to make it directional. The six holes on the ring nut and the use of incandescent bulbs but of modern conception, which therefore do not produce excessive heat, make the lamp never overheat and can always be handled. The light bulb is generous in size and occupies most of the volume of the shell, giving Orchidea a playful and eccentric look.
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Aim Create a table lamp that can also be used as suspension lamp, with a simple structure that can be modified by the user. Target The object is designed for those who need adaptability but do not give up on style.
Orchidea - Table lamp - 2017
Main features The diffuser is itself the support element. Possibility of use aslo for suspension.
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07
Cargo bike Allen
2016 - Design course in Politecnico Team work of 3 people Allen is an electric cargo bike designed to be economical to build and to meet the needs of users who require versatile products with ample load space. The shape of the frame, which excludes the vertical steering tube, increases the load space by more than 20 cm. This extra space can be used without interfering with the driver's legs. The steering system is developed with two pairs of steel cables that connect a pulley below the handlebar and one above the front fork. The aluminum platform is perforated to be light, to allow the attachment of ropes to transport stuff.
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Aim Create a bike with the same overall dimensions of the competitors, and with a bigger cargo space, acting directly on the form of the frame. Target Who uses the bike as main mean of transportation, and does not have so much space for stock it. Main features Cargo space foldable to occupy less space possible in the garage. Steering system developed with pulleys and steel cables.
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More cargo space, less space occupied The platform can also accommodate various loading accessories, such as a plastic box that increases the load volume. Moreover, it can also be folded upwards to minimize the width and ease the storage in the garage. The frame is made of aluminum. Compared to competitors, with the same maximum dimensions, the space of load is increased by 1/3.
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Allen - Cargo bike - Collab. with PandaBike - 2016
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Allen - Cargo bike - Collab. with PandaBike - 2016
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08
Bike lock Bullock vacuum locker
2018 - Design course in Politecnico Team work of 3 people The Vacuum Locker is a bike lock designed with Bullock during a Design course in Politecnico in 2018. The lock permits to free the lock of the bike from any external support like poles or racks. The working principle is the use of a suction cup to attack the bike lock to vertical surfaces. The object is composed by two vacuum cups and a steel cable.
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Aim Free the lock of the bike from external support. Permit the use of vertical sufraces as supports. Target The object is made for city bikers, living in cahotic cities with palaces, who use the bike to go everywhere. Main features Possibility to lock the bike to smooth walls, without the necessity to look for supports.
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Easy to transport
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Vacuum bike locker - Collab. with Bullock - 2018
The form of the bike lock permits to store and transport it on the bike in a very simple way. The two components that contain the suction cup are semi-spherical, so if locked together, they are able to create a sphherical shape. They have a recess shape that allows the steel cable to be rolled around and to be hanged from the horizontal tube of the frame.
Complexity for simplicity The mechanism developed permits to activate the vacuum lock just by pushing the big red button, without the necessity to use the key. The key has to be used just for the unlocking of the system. This mechanism is based on two springs and a valve. It’s not complicated and makes the working of the object completely automatic.
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Vacuum bike locker - Collab. with Bullock - 2018
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Versatility in use Not always is possible to find a smooth support to lock the bike with the vacuum locker. In that situations the object can be used as a traditional locker. The two semi-spherical elements that contain the suction cups can be joined together and activate, so is possible to obtain a traditional locker that can be used to lock the bike to a pole, a tree, or any kind of support.
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High strenght in a compact size
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Vacuum bike locker - Collab. with Bullock - 2018
The object is small, since the diameter of the suction cup is 130 mm. This dimension permits to create a force of more than 100 Kg per each semisphere, that is sufficient to secure the bike. An external rubber ring avoid the possibility to insert objects from the bottom to break open the mechanis.
09
Countertop washbasin Crystal
cristalplant
2018 - Contest for Cristalplant Individual work Crystal is a countertop washbasin designed to be realized with a technology that uses an epoxy resin based on quartz to make casts that allows undercuts. The design expresses simplicity and valorizes the forming possibilities of the material. The control of the water is based on a touch system.
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Aim Develop a simple shape taht can shows the possibilities offered by the quartz resin technology. Target The countertop washbasin is a component for bathrooms, and is adaptable to a sober and modern environment. Main features Touch panels for the contro of the water temperature and intensity; led stripe that lights up the interior.
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Formal essentiality To exalt the formal simplicity and the cleanliness of the object, the water pipe is externally located and curved to hang on the inside.
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Invisible technology
Crystal - Bathroom washbasin - Arteteco and Cristalplant contest - 2018
It’s been tried not to dirty the clean shape even with the water controls, so it’s been adopted a touch system. The motherboard on which the system is mounted is also the housing for the LED system, that permits to light up the interior of the washbasin, giving a particular and refined look at the object.
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Crystal - Bathroom washbasin - Arteteco and Cristalplant contest - 2018
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Outdoor seat Leaf
2018 - Contest for Gandia Blasco Individual work Leaf is an outdoor rest chair. The project is based on the search for a form that can be made in a single material and a single element, that don’t need surface treatments or assembly processes, using a production technology that makes it extremely economic to realize. The purpose was to find the purest form possible, which could have its own well-defined aesthetic language, creating a statuary and sculptural form without renounce to a certain lightness. The geometries respect those of the rest seats, maintaining a structure that is not cumbersome and remains stackable despite of the presence of the armrests.
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Aim Develop a unique and simple form suitable to be realized with different materials and similar productive technologies. Target The rest chair is made for an outdoor use, but can be used not only in gardens, but also in a domestic landscape.
Fold - Outdoor seat - Gandia Blasco contest - 2018
Main features The chair is realized from a single piece obtained by the cutting of a plastic or metal sheet. The finished product is obtained with seven folds.
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One design, different souls
670
800
Leaf's strong point is the possibility to obtain different surface finishes and different material and tactile characteristics acting only on the basic material of the sheet used. A focal point of the project is the versatility of realization, and Leaf can be produced starting from polymer sheets or from steel sheets. With plastic can be obtained the transparency. Monomateriality allows a low cost and reduces the environmental impact, greatly facilitating recycling and reuse. Moreover, the chairs can be stacked to gain space even during transport.
615
540
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Folding phases
1
2
3
4 69
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Fold - Outdoor seat - Gandia Blasco contest - 2018
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Extra projects
3D surface modeling AEG Liliput
3D assemblying LEGO Superbolide
FEM analysis Cheetah prostetic leg
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3D surface modeling AEG Liliput
2016 - 3D model course in Politecnico Individual work The model of the AEG Liliput vacuum cleaner was created for a surface 3D modeling exercise. The software used is Autodesk Alias for modeling and Keyshot for rendering. The reflections of light make appreciate the continuity of curvature between all the surfaces of the model.
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Surface continuity as first target The modeling was performed for surfaces, modifying the control points of the various curves that compose them to put adjacent surfaces in continuity of curvature. The continuity of curvature is also maintained between the different components of the object.
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AEG Liliput - 3D surface mdeling - 2016
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AEG Liliput - 3D surface mdeling - 2016
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3D assembly LEGO Superbolide
2016 - 3D model course in Politecnico Individual work The Lego Superbolide model was created for a solid modeling exercise. The software used is Autodesk Inventor for modeling and Keyshot for rendering. For the development of the various components, it was used the parameterization method, which allows the introduction of repetitions of standard shapes to create different components. The model was created piece by piece and then assembled within Autodesk Inventor.
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Parametrized model To parameterize the individual components, it was used a mode on Autodesk Inventor that allows an Excel file to be used to automatically change the size of the bricks. The assembly phase is been done also in Autodesk Inventor.
LEGO Superbolide - 3D mdeling - 2016
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LEGO Superbolide - 3D mdeling - 2016
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13
FEM analysys Cheetah prosthetic leg
2018 - FEM analysis course in Politecnico Team work of 2 people The project consists of a finite element analysis realized with the Abaqus software. The aim of the analysis was to highlight the maximum efforts and maximum deformations to which a prosthetic leg for competition is subject during the use. The prosthesis taken into consideration is the Cheetah Xtreme. To define the model and the material are been used the manufacturer's data.
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Case studies
TAKE OFF 1 dai blocchi
To make the analysis have been considered three extreme cases regarding the intensity of the forces during the olympic 100 meters race, taking into consideration several tests carried out on professional athletes. These tests were able to provide us the right intensity of strength in relation to the weight of the athlete, while the theory concerning running dynamics allowed us to extract the angles of action of it.
α = 45°
TAKE OFF 2 da terra
LANDING
α = 60°
F = 2800N
F = 2500N
α = 100° F = 3900N
Regola delle miscele tra resina epossidica e fibra di carbonio:
Study of the material
Epoxy Resin Em1 = 41 Gpa Vm1 = 0,3 (volume resina) Carbon fiber
To describe the material it was necessary to use the mixture rule. Indeed 30% of the composite in volume consists of epoxy resin, with different characteristics than carbon. In addition, carbon is an anisotropic material, so it has two different values of elastic modulus (E), with respect to the type of stress. This analysis has served us to understand the exact mechanical characteristics of a a single layer of weft or warp, then of a single layer of fibers. In this way we have schematized the tissues in two unidenzional layers at 90°.
Ec1 = Vm x Em + Vf x Ef Ec1 = 204 GPa
Ef1 = 231 Gpa Vf1 = 0,7 (volume fibre)
Epoxy Resin Em2 = 41 Gpa Vm2 = 0,3 (volume resina)
Ec2 =
Carbon fiber
Ec2 = 4,76 GPa
Em x Ef Vm x Ef + Vf x Em
Ef2 = 5 Gpa Vf2 = 0,7 (volume fibre)
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Modeling in Abaqus The model has been defined in Abaqus, through one shell, obtained by defining the points that generate the curve of the prosthesis. We considered 15 points to discretize at best the irregularity of the curvature, in order to have a most correct section. The curve has been extruded in depth of 60mm, creating a shell. Once the shell was created, coincident plans were created to model the areas where a change in material thickness occurs. So the shell has been partitioned, creating 11 distinct zones of the model, to which 11 thickness values correspond different, ranging between 4.5 and 10.8 mm.
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Meshing Since the geometry is simple and linear, it was chosen a quadratic and structured mesh, with square elements and 6 DOF for every knot. We have chosen elements of a square shape because the outline is not curved and does not deform them. To define which mesh to adopt, we performed an analysis of convergence, which showed that when the 3 mm seeds have been exceeded, the values remain constant. We have therefore decided to use a mesh with 3 mm seeds, in order to not excessively overload the analysis.
FEM analysys on a phrostetic leg - 2018
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Scheme of the case in exam A concentrated force was applied to be able to direct it better. Subsequently, a coupling was made on the contact surface to bring out the concentrated force as a distributed force. Since the applied load is the reaction force, the constraint has been applied to the point of attachment of the prosthesis to the knee of the athlete. The force diagram is different for each of the three cases taken into consideration, since the load and the angle is different, while the constraint remains in the same point.
Fy = 3377 N Fx = 1950 N
ι = 60° 88
MAX STRENGHT
The result of the analysis shows visible but not excessive deformations, which are comparable to what was found during the analysis of the videos and the tests found and studied. This type of prosthesis is used by athletes with both legs amputated, and this is why the bending of the object (of the order of ten centimeters) does not affect the balance. For athletes who wear only one prosthesis, it is necessary to use stiffer prostheses. The great elastic return due to the deformation of more than 10 cm is the reason why prosthetics have been banned from Olympic competitions for able-bodied athletes.
S mises max= 2049 MPa DEFORMATION IN Y U2 max = 168 mm (in the thinner section)
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FEM analysys on a phrostetic leg - 2018
Analysis and conclusion
+39 3278179375 alessio.pilo.design@gmail.com
2020
Thank you