TRAVELPACK Philadelphia University Thesis Project Brian Celenza
TRAVELPACK A backpack designed to alleviate the problems associated with airplane travel Philadelphia University Thesis Project Brian Celenza
Brian Celenza
briancelenza@gmail.com
215.407.8146
CONTENTS Background 4 Research 8 Airport Security Regulations Packing Habits and Techniques Demographic and Market Research Development 28 Sketch Development Initial Concepts Concept Refinement Prototype Development Prototype Analysis (5) User Testing Construction 52 Design Features 58 Security Checkpoint On-plane Accessibility Living Out of the Suitcase Technical Details 66 Material Selection Orthographic Drawings Pattern Construction Color Iterations Acknowledgments & References 82
Background Carry on luggage is a popular method for travelers who will be traveling for a few days and do not want to waste their time or money checking their bags. I have chosen to create backpack luggage because I feel that the current backpack market does not adequately account for a traveler’s needs. My project focuses on three specific areas that are lacking in the backpack market: Security checkpoint efficiency, on-plane accessibility, and clothing organization.
Security Checkpoint Efficiency The security checkpoint at the airport is one of the most time consuming and stressful processes because of luggage. The Travelpack takes into account new security measures regarding laptop usage and liquid/gel separation policies to speed up this process. On-plane accessibility In transit, there is a hierarchy of items that need to be accessed. Items such as clothing and toiletries rank lower than items such as passports and cell phones on the airplane. The Travelpack compartmentalizes these items and makes them accessible when needed. Living out of the suitcase Many travelers choose to live out of their suitcase for short-term travel. Most luggage is inefficient and makes a mess of clothing and personal items. The Travelpack organizes clothing so that all items can be visualized at one time.
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RESEARCH | DEVELOPMENT | CONSTRUCTION | DESIGN FEATURES | TECHNICAL
RESEARCH Travel is a complicated activity that requires in-depth research to thoroughly understand. During this process, research was compiled to designate criteria for my design. The major areas of interest during this phase of the project were airport security regulations, packing habits and techniques, and demographic and market research.
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AIRPORT SECURITY REGULATIONS Airport security is a major source of frustration while traveling. The TSA or the Transportation Security Authority enforces a number of regulations that slow down a traveler. By understanding these policies, I was able to design a bag that could improve this part of the travel process.
Liquids, Gels, Aerosols Since 2006, the TSA has required all liquids, aerosols, and gels to be under 3 ounces in size and placed in a 1 quart plastic bag for x-ray screening. Many travelers are unaware of this policy and have to dispose of their toiletries because they do not meet security standards.
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Laptop Policy Prior to December 2012, laptops were required to be removed from their carrying case and placed into a security bin for x-ray screening. However, the TSA has acknowledged this inconvenience and created a criteria for bags that do not require the laptop to be removed.
The criteria include: • A designated laptop-only section that can lay flat on the X-ray belt • No metal snaps, zippers or buckles inside, underneath or on-top of the laptop section • No pockets on the laptop-only section • Only the laptop can be placed in the laptop-only section • A completely unfolded bag with nothing above or below the laptop-only section
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Size Regulations Many airline companies have their own standard size regulations for carry-on bags. These sizes are calculated by adding up the length, width, and height of the bag. The majority of maximum airline allowances range from 45� to 50�. Weight Regulations Similar to size regulations, weight regulations vary depending on the airline company. Many US domestic flights have a higher weight allowance - ranging from 2550 lbs. The majority of international flights restrict weight allowances to 15-25 lbs.
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PACKING HABITS AND TECHNIQUES There are a number of different variables when it comes to how a person is going to pack their bag. Not only is it important to take into account how many items are packed, but it is also important to understand the different ways that people fold and organize their items.
Packing Trends and Lists Travel agency packing lists and personal packing photographs were studied to get a general understanding of how many items are being packed and any trends that exist within these items. One of the major discoveries during this process was the desire for people to bring an extra pair of shoes and how to separate them from the bulk of their clothes. Another discovery came from the increased number of personal electronics (laptops, cameras, etc.) being brought on trips.
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Standard Folding One of the most common ways that people pack their clothes is also the least efficient. The method of individually folding and stacking clothes does not pack down well and also lends itself to creases and wrinkles.
Rolling Rolling clothes is helpful in reducing the number of creases caused by folds. Rolling clothes also condenses clothing more effectively than standard folding. One major flaw with this method is an increase in wrinkles.
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Vacuum Bagging Vacuum bagging involves placing clothes into a thick plastic bag and sucking the air out of the bag. This method does not effectively prevent wrinkles and creases. Another downfall of this technique is that some vacuum systems require external pumps to remove air.
Bundle Wrapping Bundle Wrapping is a method in which you wrap individual clothes around a central core object, avoiding hard folds that cause creasing. There is a specific order of wrapping clothes; starting with shirts and ending with pants. This method’s major downfall is that when a specific item is wanted, all clothes must be unwrapped and hung up to remain wrinkle-free.
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DEMOGRAPHIC AND MARKET RESEARCH Luggage is one of the largest markets in the soft goods industry. Therefore, PLACEHOLDER IMAGEit was important to target a specific type of travel and the bag that is associated with it. I decided to target carry-on bags because I saw a rise in checked luggage fees and predicted that more people will want to bring all of their belongings on the plane and avoid those fees.
Demographic Profiles The demographic that I wanted to target was a younger generation of travelers. Travelers who are willing to pack all of their items into one single bag and are comfortable wearing this bag on their backs. The type of travel this bag is intended for is short term (3-4 days) leisure and long weekend trips.
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Andrew, 30 Family reunion Length of stay: 2 days
Jill, 26 New York City Tourist Length of stay: 3 days
Joey, 19 Visiting friends Length of stay: 1 day
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Rick Steves Classic Back Door Bag Features Can be used as backpack or duffel 2500 cubic inch main compartment Materials Recycled high density polyester
Ignoble Lorna Case Backpack Features Bag has two zipper access points Multiple ways to orient bag for carrying Materials 1680 ballistic nylon Ripstop nylon lining
Mission Workshop Arkiv Modular Bag System Features Modular bag system that uses rails to attach bags together Waterproof roll top design Materials Cordura Wax canvas VX fabric 26
V•S•T•R Travel Pack Features Bag breaks off for personal electronics Larger volume for more carrying opportunities Materials 10oz cotton duck canvas Martexin wax finish Nylon interior lining
GoRuck GR1 Ultra durable backpack Features Multiple access points into two main compartments Stress points strength tested at 400 lbs. Materials 1000D Cordura 550 paracord zipper pulls
Incase EO Travel Collection Features Designed for younger travel generation Emphasis on technology storage Materials Nylon Triple coated front panel 27
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RESEARCH | DEVELOPMENT | CONSTRUCTION | DESIGN FEATURES | TECHNICAL
SKETCH DEVELOPMENT Sketching took place throughout the entire project. Early in the project, sketching was a tool to quickly put down ideas without having to dedicate time to creating a prototype. Later in the project, sketching was critical in determining function and construction techniques.
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INITIAL CONCEPTS
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CONCEPT REFINEMENT
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RESEARCH | DEVELOPMENT | CONSTRUCTION | DESIGN FEATURES | TECHNICAL
PROTOTYPE DEVELOPMENT AND USER TESTING A number of prototypes were created to get a better understanding of the bag’s form. Prototypes started with cardboard and paper then developed into canvas models. The following pages will break down some of the prototypes and the lessons that were learned from each version. After prototypes were at a functional level, user testing was conducted to gain a different insight on the design.
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PROTOTYPING Backpack construction is one of the more complicated forms of soft goods design. Prior to starting this project, the process of sewing was foreign to me. Through numerous trial and error, I began to understand soft goods construction and gained valuable sewing experience.
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Prototype #1 Features: • Meets laptop security guidelines • Break off bag for in seat access • Bag can be set up like a “dresser” • Opportunity to become rolling bag Areas of Concern: • Construction materials do not allow for user testing • Difficult to create standing structure without internal frame (adds weight) • Maximum security size does not mean it fits body in ergonomic manner • Requires certain folding technique
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Prototype #2 Features: • All bag compartments hinge from the same location • “Rolodex” of clothing allows for easy visualization of items • Each compartment can open up flat to separate items within bag Areas of Concern: • Construction materials do not allow for user testing • High stress point on hinging point • Extra pockets/fabric adds a lot of weight to bag
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Prototype #3 Features • Laptop becomes exposed by folding in three different orientations • Bag can be set up like a “dresser” • Compartment shape is ambiguous • Functional model for testing Areas of Concern: • Bag connection point is not secure • When opened for security, bag is larger than average belt width • Forces user to pack items in condensed pockets likely to cause wrinkles
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Prototype #4 Features: • Clothing compartments open up in spread out manner • Flat sleeves allow for standard folding • Internal sleeves allow for organizational layering of clothing • Overlapping connection of compartments keeps bag tight Areas of Concern: • Limited pocket opportunities for objects besides clothing • Laptop safety is questionable
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Prototype #5 Features: • Fully functional prototype for testing • Clothing compartments can open flat for better visibility • Break off bag for in-flight access • Central strap tightens bag together Areas of Concern: • Construction technique is complex • Break off bag connection point is not fast and easy • Aesthetics and material choices
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USER TESTING After the first working prototype was constructed, a series of user testing was conducted to determine how desirable the scale of the bag was and ask questions about what the user felt the bag was missing. This step in the process was crucial for moving forward with the next prototype.
Items Packed In Front Pouches: Flannel, jeans ; T-shirts (3), Sweatshirt ; Underwear (3), Socks (3), hat, marker, pencil, deodorant, toothbrush, toothpaste, phone charger Items Packed in Back Pouch : Nothing
Items Packed In Front Pouches: Scarf, big headphones; hairbrush, underwear(3), bras(2), glasses case, hairbrush; shoes(1) Items Packed in Back Pouch : Sweaters(2), dress, blouses(2), jeans (1), t-shirt, sweatpants
Items Packed In Front Pouches: Toothbrush, deodorant, retainer; shoes in plastic bag; Underwear(3), socks (4) Items Packed in Back Pouch : Jeans, sweatpants, Polo shirt (3), Dress shirt, t-shirts(4)
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Items Packed In Front Pouches: Flannel, hat, ipod, camera, notebook, reading book, pens ; towel, toothpaste, deodorant, comb ; sleeping bag Items Packed in Back Pouch : T-shirts (3), Jeans, Underwear (3), Socks (3)
Items Packed In Front Pouches: Glasses case, toothbrush, retainer, personal care toiletries, floss, mirror, contact lens; yoga mat, brush, makeup; two sandals in bag Items Packed in Back Pouch : Jeans (1), shirts (2), sweater, dress, bra (2), tank tops (2), yoga pants (2), underwear (3), bathing suit
Items Packed In Front Pouches: Toiletries (hair spray gel, shampoo, chapstick, deodorant), jewelry, comb; Underwear (3), Socks (3), tights, scarf (3), yarn; shoes (2) Items Packed in Back Pouch : Dress, 2 jeans, 3 sweaters, tank top, blouse, sleep shirt, athletic shorts
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RESEARCH | DEVELOPMENT | CONSTRUCTION | DESIGN FEATURES | TECHNICAL
CONSTRUCTION Soft goods construction involves strategic planning and efficiency in order to be successful. Through numerous sketches and trial bags, a realistic construction method was designed that would allow me to create a final prototype.
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Dimension and Construction Planning
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RESEARCH | DEVELOPMENT | CONSTRUCTION | DESIGN FEATURES | TECHNICAL
DESIGN FEATURES After a series of prototypes and sketches were analyzed and moved forward, a final design was established that met the criteria in improving the user’s experience at the security checkpoint, on-board the airplane, and at the final destination.
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Security Checkpoint The Travelpack takes advantage of the new laptop policies by opening flat for easy scanning. The laptop becomes exposed by a series of plastic clips as opposed to most competition which uses zippers. The laptop can be easily accessed from a roll-top padded compartment if requested by agent.
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On-plane Accessibility The Travelpack has a portion of the bag that can break off and sit in the seat pocket on the airplane. This section of the bag is easily detached by two plastic clips. Pocket sizes were strategically sized to accommodate for travel documents and personal electronics, two things that were requested during user testing.
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Living out of the Suitcase The Travelpack makes it easy to live out of the suitcase by opening up flat for easy visibility. The top clothing portion can be broken off using zippers to be displayed in hotel setting. Clothing compartments all open up in same orientation to prevent fabric overlapping.
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RESEARCH | DEVELOPMENT | CONSTRUCTION | DESIGN FEATURES | TECHNICAL
TECHNICAL DETAILS A technical packet containing materials, orthographic dimensions, and patterns was created that would be able to explain the Travelpack to a cut&sew manufacturer.
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MATERIAL SELECTION Through numerous trips to Philadelphia’s Fabric Row, research on various fabric blogs and consultation with experts, a material was chosen that would be lightweight yet strong enough for a traveler’s needs.
Material Selection Nylon was chosen as the primary bag material because it is lightweight, tear resistant, and can be waterproof when coated properly. 420D nylon is a popular fabric for outdoor backpacking because it is light yet can take a lot of stress.
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420 Denier Nylon Packcloth - Outer shell
200 Denier Nylon Oxford - Bag liner
Nylon Webbing - .75” & 2”
YKK Gold Zippers 71
Orthographic Drawings A series of basic orthographic drawings was completed to assist in the manufacturing process. In order to understand the bag’s function, orthographics were created for different stages of the bag’s life: all together in one unit, opened to showcase laptop, and opened to showcase clothing
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12 in.
9 in.
14 in. 73
Laptop scanning
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7 in.
20 in.
16 in.
Living out of the Suitcase
36 in.
16 in. 74
8 in.
7 in.
Three Bag Diagram The Travelpack effectively combines three bags together using zippers, clips, and a large strap that runs down the center of the bag.
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Pattern Making Pattern making for the bag developed through a series of prototypes to determine the best construction technique. Patterns were made in Adobe Illustrator and laid out on 60in. fabric for efficiency. The green nylon 420D is 48in. long and the gray nylon 200d is 42in. long.
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Top Section - front panel
Back Panel Foam Cover Bottom
Back Panel - Exterior
Back Panel Foam Cover Left
Back Panel Foam Cover Right
Back Panel -Inside Front Section- Front Panel
Laptop Section - Accent front
Laptop Section - Accent back
Major clothing compartment - Side panel
Front Section- Side Panel Left
Major clothing compartment - Exterior Bottom
Front Section- Side Panel Right
Top Section - Top panel
Major clothing compartment -Exterior top
Top Section - back/bottom panel
Major clothing compartment - Lining Side panel
Major clothing compartment - Lid Major clothing compartment - Lining Bottom
Front Section- Outside Pocket liner
Top Section - right pocket
Front Section- Interior Middle Pocket Liner Bottom Top Section - left pocket
Top Section - left pocket Front Section- Interior Middle Pocket Liner Bottom
Front Section- Interior Middle Pocket Lid
Front Section- Interior Bottom Pocket Liner Side Left
Front Section- Outside Pocket liner
Front Section- Interior Bottom Pocket Liner top/bottom
Laptop Section - Front panel Laptop Section - Back panel
Front Section- Hidden Pocket liner
Front Section- Hidden Pocket liner
Top Section - right pocket
Laptop Section - Side panel
Front Section- Interior Bottom Pocket Liner Side Right
Front Section- Interior Middle Pocket Liner Bottom/Sides
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ACKNOWLEDGMENTS
I would personally like to thank the following people for their assistance and encouragement in the completion of this project: Hy Zelkowitz Gotz Unger Orly Zeewy Joseph Peters Todd Kramer The helpful folks at Gaffney’s Fabrics All of my user testing subjects All of my bag models My friends and family
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REFERENCES BACKGROUND http://4.bp.blogspot.com/_g5N-PvvF34c/TJtrat10g6I/AAAAAAADrJU/DvHerS8wl2k/s1600/In+Line+at+DCA.jpg http://static.indianexpress.com/m-images/Mon%20Nov%2007%202011,%2017:53%20hrs/M_Id_246611_Airport_screening.jpg http://images.sodahead.com/polls/002346541/4745601600_aisle_seat_airplane_jokes_answer_2_xlarge.jpeg http://nubry.com/wp-content/uploads/2012/08/overpacking-weekend-getaway-what-to-pack.jpg
AIRPORT SECURITY REGULATIONS http://media.cmgdigital.com/shared/lt/lt_cache/thumbnail/615/img/photos/2012/10/23/2d/12/TRAVELERS.jpg http://love-and-adventure.com/lurve/wp-content/uploads/quart.jpg http://www.lseairport.com/uploads/content_files/311.jpg http://www.mobileedge.com/wordpress/wp-content/uploads/2009/12/scanfast-briefcase-on-x-ray-belt.jpg http://traveltips.usatoday.com/DM-Resize/photos.demandstudios.com/getty/article/171/16/76750038_XS.jpg?w=560&h=560&keep_ratio=1 http://boardingarea.com/blogs/deltapoints/files/2012/01/bag-fits.jpg
PACKING HABITS AND TECHNIQUES Http://iampacked.com/blade-g-albury-to-melbourne http://iampacked.com/blake-golden-plains-music-festival http://iampacked.com/eric-lin-tokyo http://iampacked.com/adam-engstrom-london http://iampacked.com/mark-bali-singapore http://1.bp.blogspot.com/-RXveQfa7EqA/T5mFzSvJvxI/AAAAAAAACVs/maXoMqSxfhU/s1600/Stack+o+clothes.jpg http://ashwoodmanor.co.nz/wp-content/uploads/2012/10/roll.png http://www.cardboardboxes.ie/images/vacuum-seal-bags.jpg http://www.1bag1world.com/storage/bundle.jpg
DEMOGRAPHIC AND MARKET RESEARCH http://www.hollandoutpost.com/wp-content/uploads/2013/03/LuggagePacks.jpg http://www.exudemagazine.com/wp-content/uploads/2010/10/Hunting-Jacket_main.jpg http://www3.assets-gap.com/webcontent/0005/886/187/cn5886187.jpg http://archdezart.com/wp-content/uploads/2012/11/ollie-carhartt-wip-2012-fw-collection-editorial-4.jpg http://travelstore.ricksteves.com/images/products/bg-xr_03.jpg http://c745.r45.cf2.rackcdn.com/img/2009/ignoble_lorna.jpg http://www.carryology.com/wp-content/uploads/2012/05/arkiv-field-pack-large-dark-gray-cordura.jpg http://www.essentialstyleformen.com/wp-content/uploads/2013/03/VSTR_Nomadic_Backpack.jpg http://cd4.newhiker.com/media/goruck_gr11.jpg http://files.doobybrain.com/wp-content/uploads/2012/12/incase-EO-travel-backpack.jpg
MATERIAL SELECTION http://3.bp.blogspot.com/-Jf0RWbKZmdY/Tw80SjDyntI/AAAAAAAAAxo/uCIDwTml3Hg/s1600/Mood+fabric+rolls+1+010712.JPG http://www.magnafabrics.com/images/420dt66.JPG http://www.onlinefabricstore.net/images/products/CNOSIL-FR_1.jpg http://img0.etsystatic.com/000/0/6070667/il_fullxfull.187631128.jpg
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