ANDREW FLYNN Product Design Engineer Portfolio 2014
coroflot.com/andrewflynn
1.
NOVA (MASTERS THESIS) Brief: Design a product which streamlines airport transit. 10 month
Individual project
Project overview My final year project was carried out in collaboration with Airbus, Bauhaus Luftfahrt and British Airways. A number of other industry partners were also involved at intervals throughout the project including BMW, Siemens, Daimler Benz and Bombardier. My project focused on improving the airport experience by streamlining the passenger process.
Key Insights Three key insights drove my final year project. The airport process is filled with repetitive passenger document checks (passport, boarding pass, landing cards etc) which lead to lengthy bottlenecks. Airports offer a poor means of delivering passenger travel information causing stress and confusion. Late or missing passengers cost the airline industry up to 600$ million dollars per year due to delayed flights.
Awards:
Design Comendation Winning transport product 2014
TRAVEL MADE SIMPLE Nova Overview
Modular strap
Nova
Nova is a wearable product which streamlines airport transit for passengers’ by eliminating the need for repetitive manual document checks. Passengers can pass through checkpoints instantaneously, dramatically cutting the airport transit time at departure, connections and arrivals. Airlines can utilise Nova by tracking passengers through an airport terminal, improving aircraft scheduling and reducing delays. Passengers also benefit from this by receiving key travel updates direct from the airline.
Fastener
Biometric identity
Modular design
Indoor positioning
One travel document
Travel updates
Enables seamless travel
1. Translucent silicon cover 2. Flexible TPU casing (upper) 3. RGB LED matrix
Technical Details Nova consists of a series of lower power electronic components which together make up its function. The product casing houses an internal electronic sub assembly which contains a reflectance pulse sensor, Wi-Fi tranceiver, Lithiumion battery and an LED matrix display.
4. Flexible TPU casing (lower) 5. Removable strap
6. Pulse sensor + PCB 7. LI Battery
IMPEDED TRAVEL CHAIN Airport Overview Airport transit is a slow and time consuming process for passengers. This is due to a series of bottlenecks caused by a multitude of repetitive passenger checkpoints. The volatile nature of airport queues leads to unpredictable waiting times which, has lead airlines to enforce a minimum pre-departure arrival time for passengers. On average, a passenger will spend one third their travel time in airports. With the number of passengers constantly increasing this disjointed and dated system is working at capacity and requires a solution which is both cost effective and with minimal infrastructural change.
Check in
Security access
Border Control
Boarding
Connection check
Travel document
Landing Card
Boarding
PASSPORT Travel document
Landing Card
Flight 2KJ
PASSPORT
Boarding Pass
Landing Card
Flight 2KJ
Travel document
Boarding Pass
PASSPORT
Flight 2KJ
Travel document
Boarding Pass
PASSPORT
Flight 2KJ
Landing Card
Boarding Pass
Travel document
Flight 2KJ
PASSPORT
Boarding Pass
Flight 2KJ
Travel document
Flight 2KJ
PASSPORT
Boarding Pass
Destination
Boarding Pass
Enter Airport
Border Control
What users want
What If?
Time spent interviewing and observing passengers lead to a range of key insights which were used to develop Nova. Many passengers sought a system whereby they could flow through the airport seamlessly. Attempts have been made to create an unimpeded travel process, however current concepts all require time to process passengers when they reach a checkpoint, which leads to bottlenecks.
Passengers were able to pass through checkpoints instantly without being stopped, creating a truly free flowing airport.
Pre-checked passengers
Airport Overview
SINGLE PASSENGER TOKEN
It was clear from studying the airport passenger experience that the multitude of paper travel documents is a cause of stress for passengers. A common problem which was highlighted by many travellers was that having to constantly remove passports and boarding passes increased the risk of losing them. Furthermore, extra documentation such as landing cards are often a cause of confusion due to a lack of consistency with how and when they are used. An opportunity was identified to combine this array of documents into a digital format stored on one wearable device, attached to the passenger throughout the journey.
Feedback from Bauhaus Luftfahrt suggested this system could be extended to combine tickets and documentation from every mode of travel into one multi-modal travel key of the future.
Material
Passengers no longer need to carry a stack of paper documents each time they travel, worrying whether or not they have lost their passport. Nova is an all in one travel product which helps lighten the load and ease the mind.
Travel products, such as passports, are designed for use for up to ten years. It was important to select a material which was not only suitable for the design but cost effective and durable. Using Cambridge Engineering Selector, TPU was chosen as the main material for the product casing. This material is flexible, cheap and very long lasting.
UNIMPEDED TRAVEL Enter the airport
Confirm and store identity on Nova
Pass Instantly Nova uses a Wi-Fi transceiver to communicate with the world around it. A valid passenger identity stored on Nova means there is no processing time required at a checkpoint. Nova wirelessly communicates with the gate when it comes within a determined radius, transmitting the valid passenger ID. The gates open on approach permitting a seamless walk through experience.
Seamless Travel The key challenge was to design a product or system which allows passengers to pass through the airport unimpeded. A wearable product was developed which was able to store a passengers identity and detect when it was being worn. In doing so, the passengers identity would remain valid so long as the product remained attached to the user. After entering the airport, passengers would carry out an initial identity check at a self service kiosk. Using the kiosk, Nova would be tagged with the validated passenger identity, storing it until taken off. So long as the device remains attached, passengers are able to pass through identity and travel document checkpoints without having to queue, dramatically increasing the speed of the user journey.
Destination Check in
Security access
Border Control
Functional Prototype A functional prototype was developed towards the end of the project. This proof of concept model is able to detect when it has been
Enter Airport
attached to the user, transmitting the sensor data to a receiver where it displays which state the device is in; being worn or not being worn. This functionality determines whether the passenger details remain valid.
Boarding
Border control
TAMPER DETECTION Key Challenge After being stored on Nova, a passengers identity will remain valid so long as Nova remains attached to the user. This is the key premise behind the design of Nova. To achieve this functionality the product required a means of tamper detection. A range of initial concepts and functional prototypes were created which were able to detect when they were either on, or off, the user. A range of sensors were tested using an Arduino to carry out different commands. The key to this design was to ensure the detection method was reliable and most importantly secure and tamper proof.
After storing the passenger identity, Nova ensures it is connected by means of a pulse sensor. Light is used to measure the changing volume of blood creating a PPG waveform. Software detects the pulse and knows it is being worn by the user as a result. If no pulse is detected the device has been taken off, rendering the identity invalid.
Heartbeat as a travel key Sensor Separation
Light propagation
Photon diffusion theory used to calculate the sensor separation required for a maximum transmission depth of light of 2mm in tissue.
Beer-Lambert law was used to calculate which wavelength of light is most suitable for pulse detection. Green light at 500nm is absorbed easily by hemoglobin, a green LED was chosen for the design.
z0 (x) =
2 1⎡ 2 ⎡⎣ x 2 + (d − x)2 ⎤⎦ + 32x 2 ( d − x ) − x 2 −(d − x)2 ⎤ ⎢ ⎥⎦ 8⎣
log10
Light transmission vs wavelength!
I0 = ε lc I
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LED
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Light transmitted %
After a testing a range of different concepts with users, feedback showed using an optical pulse sensor was the least invasive and most reliable option of detection. Giving passengers the ability to pass through the airport without requiring a physical check meant the means of detection had to be secure and tamper proof. Pulse detection is very difficult to imitate unlike other biometrics like a finger print. A reflectance pulse sensor was used with arduino as a proof of concept.
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MODULAR DESIGN Sensor placement
British Airways
The reflectance pulse sensor was used along with Processing software to determine body locations a pulse can be measured from. This was used to determine where the product could be worn. Pulse can be measured anywhere there is capillary tissue close to the surface.
Early in the project a partnership with British Airways was formed. This lead to a tour of Heathrow Terminal 5 as well as the BA headquarters and engineering department. Nova was presented at BA to a range of employees from different departments. This produced a range of valuable feedback and insights which influenced the design.
Inclusive Design One of the key points British Airways raised was that the product should not be limited to one body location as it could limit the size of user group. BA suggested making the product modular allowing it to be worn at different body locations.
Product placement Having previously determined body locations capable of measuring pulse, feedback from BA was considered and a modular design was developed. A range of visuals and 3D models were used to develop the design of the module.
User feedback showed the most convenient placement of the product was the wrist.
PERSONAL TRAVEL GUIDE Travel information
Design Opportunity As a wearable device, Nova provides the perfect platform for real time travel updates direct to the passenger. A series of interface tests were carried out with users. Power consumption was a key factor and as a result an LED matrix display was selected for its versatility and low energy useage.
Observational research showed that travel updates, in their current form, confuse passengers. At several points throughout the airport journey the same phenomenon occurs: passengers, standing staring, blankly at an information heavy screen. Trying to locate the relevant travel information is not only stressful but slows down the travel process.
Passenger attaches Nova and LED strips glow yellow to indicate device is attached but is waiting for ID verification. The matrix displays a pulse wave indicating the Nova is connected.
After verifying passenger identity the LED rows glow green. Nova then displays the next mode of travel the passenger is due to take that day.
Battery
Wi-Fi
LED
MCU
AFE
PD
LED array
Using the one button on the side of Nova, users can scroll through the different interfaces. The button is held on to turn the device on and off. Time until next departure is displayed here.
LED matrix
In the airport Nova can be used to display key travel updates like gate number. If a passenger is unsure of directions Nova can be used to guide the passenger using prompts of near by landmarks.
TRACKING The Problem
the passenger or to go without them. This would save airlines time and money while reducing delays for other passengers.
Airside
Landside
Delayed or missing passengers cost the airline industry a total of $600,000,000 per year due to the extortionate costs of grounding fees at airports. At present, airlines only know if a delayed passenger is either landside or airside (as seen in figure 2c). With no way of knowing exactly where a passenger is within the terminal building, it is impossible to schedule departures accurately. If airlines were to know a passenger’s location they could then work out whether it was worth waiting on
Solution - Beacon - Signal range
Indoor Positioning System Passenger tracking is enabled for airlines and airports by using a series of indoor beacons which measure the received signal strength from near by Nova devices.
- Passenger
Several experiments were carried out to determine a method of tracking. Testing showed received signal strength indication (RSSI) varies logarythmically with distance. Using a transmitter and set of receivers a fully functional proximity based indoor positioning system was created.
- Gate Receiver
Internal Product Structure
Transmitter
X(m)
RSSI vs Distance 70
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LI Battery
Wi-Fi tranceiver
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A FAMILY OF PRODUCTS
Target Market Interviewing and observing a range of different passengers at Heathrow and Glasgow airports helped define the target market for Nova. Nova would be sold by airlines to passengers looking to improve their passenger experience and streamline the journey. Therefore, the target market is those who are willing to pay for the added benefits Nova can provide. User research showed the most likely users would be families and those traveling on business. Research showed that many frequent flyers travelling on busisness do not fly business class and that the airprot was often the most stressful part of the trip. Nova offers a solution which dramatically improves the airport experience but for a fraction of the price of a business class ticket.
Family Friendly Easy ID:
User Acceptance Tests It was important to gain feedback from some of the key traveller types to determine if they would mind wearing Nova throughout the entire trip. Two separate users were given the product to take with them on a trip. Feedback stated neither passenger found wearing the product an inconvenience and would be happy to wear it given the added benefits.
Proximity:
Out of range:
DESIGNED FOR EVOLUTION Enabling Technologies One of the key aims of this project was to identify new technologies and processes which would enable a future of better travel. Not only does optical pulse sensing offer a means of tamper detection, it also has room to evolve.
Pulse Based Biometric Identification According to literature studies different people produce different pulse waveforms due to the changes in shape and position of their heart. These changes are unique to an individual and therefore have potential to identify someone. Using the pulse sensor and graphing software, pulse was recorded from a range of different subjects. As seen in the traces, each waveform set is unique. Each person’s pulse was taken twice, one week apart. Although pulse was measured at different times the shape of the waveform stayed the same. This is good evidence that this form of biometric has potential to be used as identification.
Personal Autonomous travel Pulse biometric identification would enable Nova to be a truly all in one travel document. Passengers would no longer require any checks of any kind within the airport, with all checks carried out on Nova. This next step in computing technology is just around the corner and Nova is ready to provide the user platform.
Project Collaboration Nova was designed to work within a larger travel concept which I helped develop along with two course piers during our masters year. The overall concept consisted of a new flexible cabin design and a modular aircraft capsule loading concept in combination with Nova.
FINAL DESIGN Detail Design A series of technical drawings were produced for Nova which conform to BS 8888. These drawings were used to specify the construction, manufacture and surface finish of the different components within the device. Using these drawings, accurate final models of the design were possible to make.
QTY. 1
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UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH: TOLERANCES: LINEAR: 0.1mm ANGULAR: 0.1mm NAME
DEBUR AND BREAK SHARP EDGES
FINISH:
SIGNATURE
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DO NOT SCALE DRAWING
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TITLE:
Exploded Isometric
DRAWN CHK'D APPV'D MFG Q.A
MATERIAL:
WEIGHT:
DWG NO.
SCALE:1.5:1
A3 SHEET 1 OF 1
Final Prototypes The final aesthetic models were made from a series of different processes. The main body of the product was 3D printed in Nylon using SLS giving it a high quality surface finish. The body was then given colour by applying thin layers of spray paint. The strap was initial 3D printed and then a mould made from this part out of plaster. Silicon was then used to cast the strap giving it the desired functional properties. Small amounts of oil paints were used to die the silicon giving each strap a unique colour.
2.
THE HORIZON SYSTEM Brief: Rethink door to door travel in 2050 3 month
group project
Project overview This project was set by Airbus as phase one of a two year long project rethinking door to door travel in the future between megacities (population over 10 million). Following this project I spent a summer working in Munich at Bauhaus Luftfahrt which led on to my final year project. This phase of the project took a blue sky thinking approach to create radical concepts for door to door travel. I also had the opportunity to work with Pixar movie director Mark Andrews helping create an awad winning animation of the concept.
Key Insights Much of the time in a door to door journey is spent travelling to the airport. This is due to the size and density of megacities and the congestion due to the ever rising population.
Awards: Featured:
Winner - Pixar Creative Award
IDEATION Outside the box Unlike other design projects, the futuristic nature of this project helped free up the imagination and explore concepts which may not usually have been explored. This approach proved to be very beneficial as it meant all concepts were considered in full.
DESIGN DETAIL Three components Three main components were identified for detailed design within the Horizon system. The inner city airport, the Skystation, the transfer pod, Skylink, and the Horizon aircraft, used to pick up the moving pods. Illustrator was used to detail the design of the different components.
Concept development After carefully planning out each component of the system, Autodesk Alias was used to turn the 2D drawings into 3D. The Skystation was the exception to this being built in Sketchup.
FINAL CONCEPT Visualisation A series of high quality visual renders were created for a print publication given to Airbus. After receiving some media attention, the renders have now been used in a series of magazines around the world. All renders were carried in Keyshot with post processing in Photoshop and Illustrator. A three minute animation was also created to showcase the concept which was also picked up by several design blogs and the BBC. The animation can be found at: https://vimeo.com/64725811 The publication can found at: http://issuu.com/andrewflynn1/ docs/publication_2.5
3.
THE BULL LOCK Brief: Design a bike lock that prevents theft and encourages cycling. 3 month
group project
Project overview This project was carried out as part of the international Hands Off My Bike NESTA competition. The goal of the project was to design a new type of bike lock that would deter theft. The Bull Bicycle Lock was shortlisted from an international pool of applicants for final testing and judging. This product is still under development.
Key Insights Public bike locking infrastructure is unreliable and often overcrowded. Cyclists carry personal locks as it allows them to lock their bikes to public infrastructure. However, secure bike locks tend to be large, heavy and awkward to carry. As a result, cyclists compromise by buying less secure locks which often leads to theft.
Awards:
Hands Off My Bike! finalist
DISCOVERY + IDEATION Initial testing was carried out on a range of bike locks in order to determine which of the current designs is most secure. A range of locks were purchased and a range of different cutting tools were used to test the strength of each lock. Many of the locks were cut in under 10 seconds with a miniature hack saw or a pair of pliers. The D-Lock and chain lock were the most resilient, however the size and weight of these locks make them impractical to carry. Furthermore, a pair of heavy duty bolt cutters are able to break each of these in under 10 seconds.
Strap lock
Handlebar lock
Spinning core lock
Personal bracket lock The key challenge was to design a lock which was more portable than current bike locks and more secure. Sketching, prototyping and CAD
(Solidworks and Sketchup) were used to develop a range of initial concepts. These were then evaluated against a set of criteria determined in the research phase of the project. The integrated handlebar lock was chosen for further design development as it matched the design criteria best out of the initial concepts.
User experience testing A series of different handlebar concepts were designed and built for users to test. Quick mock ups were used to test different user interactions with the lock in order to evaluate and iterate the design. Video prototyping was also used as means describing the concepts to users who did not have access to a physical prototype.
Storyboarding Using early CAD work, I was able to create storyboards which I used to describe some of the key interactions in more detail. The majority of the CAD was carried out in Solidworks for this project and rendered in Keyshot.
FINAL DESIGN The final design of the Bull Lock consists of a central locking unit and stem clamp and two detachable steel bar ends used to lock the bike. A working prototype was made by heat treating and bending steel tubes and milling the central locking unit. The central unit also has room to mount brakes. The design was shortlisted for the finals of the Hands Off My Bike competition.
4.
PLUGGO Self set brief: Improve the Apple “out of wall� experience 3 month
group project
Project overview Pluggo was an extra project carried out during my final year. The project came about over the Christmas period when a course mate and myself were looking to do a short design project before starting the second semester. The project ended was developed throughout our second semester and was shortlisted for the final four in the Deutsche Bank Start Up Award.
Awards:
Award finalist
Available at:
Key Insight The low profile, minimal design of the Apple plug makes it difficult to remove from a UK style socket. This insight was first identified while speaking to a course mates mum about what she finds annoying in her day to day life. After speaking to a range of Apple users, it was confirmed that several people find this to be an issue.
DEVELOPMENT Sketches were used during the initial ideation phase of the project to help explore how a grip product could be added to the plug. It was important to determine the maximum distance the plug could be from the socket while being able to draw power. Simple tests using cardboard showed that 3mm was the maximum separation possible.
A range of different designs and mechanisms were 3D printed and tested with Apple plugs. It was important that the design could be used with all Apple plugs (which vary in shape and size) and therefore different hinge designs were tried and tested.
FINAL PRODUCT Pluggo is a small and portable Apple charger grip which can also act as a small ledge to hold your phone while it’s charging. A folding handle provides an easy to use grip when pulling the plug from a socket. When not in use, the handle folds back into the profile of the plug maintaining the low profile and portable design. The final design can be found on Shapeways where it is available to purchase.
BUSINESS VENTURE After finalising the design of Pluggo, it was used as a platform to demonstrate a potential new manufacturing process for low level production. This was pitched as a new business venture which placed in the top four of this years Deutsche Bank Awards. Moulds were created for Pluggo which were then used for casting. This enabled a range of high quality Pluggos to be made at a fraction of the price of 3D printing. This was used to help demonstrate the intended process of injection moulding into 3D printed moulds.
Casting process
Polyurethane Pluggos
5.
NCR PORTAL Brief: Design an ATM you would cross the street to use. 3 month
individual project
Project overview This was a three month industry project carried out with ATM manufacturer, NCR. We were tasked with designing an ATM you would want to cross the street to use. This project takes a user centric design approach to improve the experience of using an ATM at night. The project was part of a national competition run by NCR which involved students pitching their final concepts to a panel of judges at the end of the project. My concept, Portal, won the NCR Design Competition 2012.
Key Insights ATMs have been made to function 24 hours per day however, they have not been designed to adapt to user needs between day and night time environments. Most ATM users feel uncomfortable using an ATM at night saying the process took too long.
DISCOVERY + IDEATION Research Methods A range of different user research methods were carried out during this project. A combination of observational user research and field interviews were used to gather a range of key insights. Feedback from ATM users were gathered and used to create user profiles which were later used as a means of evaluation when testing concepts.
After a period of sketching and ideation physical prototypes were used to test and further develop functions and interactions of the ATM.
Main body of the prototype created using vacuum forming. The sphere creates a seamless internal surface making it impossible to hide any form of skimming device without it being noticed.
APP DEVELOPMENT
Along with the design of the ATM I also decided to develop an APP which would be used to guide users to the nearest ATM at night. Classes in information architecture helped plan out the application and how it would fit into the user journey.
Using an open source app creator I was able to design and prototype the key features of the app and use it on my iPhone. This was a useful way to let others try the app and give me feedback on its design.
DETAILED DESIGN Research Methods A 1:1 scale prototype was built which was used as part of the NCR design competition. Building this prototype allowed me to experiment with the lighting system in the ATM and how it would be used to guide a user at night. The final prototype was made from a vacuum formed sheet of plastic, laser
cut acrylic components and a series of LED strip lights wired in parallel. This prototype helped me finalise the design a provided a useful platform to showcase its key features.
FINAL DESIGN Portal transforms at night, only providing streamlined cash withdrawals allowing users as quick a transaction time as possible. The lighting system guides users through the transaction process reassuring the user of the streamlined process. The iconic green ring is unique and easily identifiable at night.
THE APP Locate a safe ATM in a safe environment with NCR night APP.
6.
CABIN + GH VEHICLE Brief: Increase seating capacity for A320 and decrease turnaround 3 month
group project
Project overview Three month internship at future transport design think tank based in Munich. This project was split into two sections; future cabin designs for an A320 sized aircraft and the design of a rapid turn around ground handling vehicle. Aim of the project was to increase overall efficiency and performance of a short to medium hall aircraft.
Key Insights Future trends suggest the amount of baggage passengers travel with is decreasing meaning many flights travel with little to no cargo. Much of the downtime of an aircraft is spent taxiing to and from the terminal at slow speeds. This time could be utilised for boarding and deboarding passengers.
Intern:
CABIN DESIGN The cabin was designed with three distinct classes and areas; super economy, economy+ and business+. The business area makes use of space on the lower deck of the aircraft using staggered seating giving a sense of personal space. The cabin also featured new overhead luggage bins and a folding seat concept.
GROUND HANDLING Detailed analysis was carried out of the current turnaround process and opportunities for improvements identified. A range of vehicle and system designs were created exploring how passengers could dynamically board and deboard an aircraft.
The novel ground handling vehicle was designed to work with any aircraft, however the performance is optimised when used with the new cabin design. The new vehicle also reduces the required GH vehicle count to four. In combination, system analysis showed turnaround times could be reduced by up to 61% and the cabin passenger density increased by 45%.
Articulated Air Bridge
5.
OTHER WORK ProControl Cycling Prosthetic: Utilising additive manufacture for custom fit prosthetic
Human Factors: Redesign of the Fitbit sleeping wristband and sleep mode function
Electric Search and Rescue Snowmobile: Mechanical design engineering project in a multidisciplinary team
References
“
IMPRESSIVE! The first word that comes to mind when I think Andrew Flynn. There are many other words to describe him as a Product Design Engineer- all of them equally positive, but the first word is impressive. I met Andrew while teaching at GSA last spring. He was leading a team of talented folks and they presented there solution to global commuting- HORIZON. I was blown away. It was impressive. I was lucky to work with Andrew and help refine his pitch and how he addressed notes and iterated on his presentation and ideas was impressive. HIRE this man! He has everything you need. A fantastic imagination, an understanding of engineering and a sense and compassion for who and what you are designing for. Collaborative and inventive he would be an asset to any project.
”
Mark Andrews: Director at Pixar
“
Andrew was the winner of the 2012 NCR | Scottish Student Design competition. Developed over a six week period his concept was well researched and his design realisation both innovative and beautiful. Andrew’s final presentation was very professional in delivery and his model and supporting visuals were of a very high standard. He set a very high standard for the competition.
”
Charlie Rohan: Director, Consumer Experience at NCR Corporation
THANKS FOR VIEWING! More projects can be found at: coroflot.com/andrewflynn