Transportation
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Over half a century of transport design.
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Welcome
Founded in 1960, we are one of the world’s leading product design and development consultancies, operating globally from our campus in Warwick, UK. Since the early sixties we have helped a wide variety of companies design and develop market leading products that users still value every day, ranging from the Stanley knife to the Eurotunnel Shuttle.
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Today we focus on building long term relationships with large corporations in four market sectors: ‘Medical and Scientific’, ‘Consumer’, ‘Commercial and Industrial’, and ‘Transport’.
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Our History
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In 1960 David Carter CBE RDI founded David Carter Associates (DCA) as "a multidisciplinary consultancy involved in designing products for mass production".
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Today
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The Old Library is one of our studios often used for transport design projects with secure access to keep sensitive information confidential.
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Our expertise
We add value by improving the success of product innovation We do this through an intelligent appproach to design, based on the transparent management of risk, informed decision making, true integration of disciplines and rigorous development processes. We believe that the outstanding commercial success of the products we help create is dependent ultimately on delivering exceptional value to our clients customers. We provide the right blend of strategic thinking and pragmatism to deliver our clients’ projects successfully.
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We balance the creativity and the technical discipline needed to achieve commercially successful product innovation. Every client is unique. To support our clients, we like to understand them, their place in the market and their ambitions thoroughly.
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Our Awards
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We have won over 35 international awards in the last five years.
Multi award winner
Multi award winner
Multi award winner
multi multi
gold
winner 2015
Stanley Caplan User-Centered Product Design Award
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Our People
DCA is a collection of over 130 extraordinary individuals. Intelligent, creative and thorough, our people make the difference to our clients’ projects. They combine to create a vibrant fusion of disciplines including mechanical engineers, electronics and software engineers, industrial designers, usability and interaction experts, researchers, strategists, prototyping technicians and specialist project managers. Each person is an expert in their own field, but has the curiosity, understanding and flexibility to reach
across traditional inter-disciplinary boundaries. Our organisational structures and team culture encourage this synergistic blending and integration of specialist skills. Our clients benefit not only from each individual’s depth of knowledge and experience but also from a team whose combined strength exceeds the sum of its individual members’ expertise.
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Our connected disciplines
Since our foundation a multidisciplinary philosophy has been the cornerstone of our approach to product design and development. DCA’s specialists offer robust tools and techniques in every field of product design and development, but it’s the connection between these different disciplines that we believe make us unique. Our studios, laboratories and workshops have different disciplines working side by side. Our ability to connect and integrate the right disciplines, at the right time, in the right way is the cornerstone of our approach.
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There are no departments at DCA. Our studios, laboratories and workshops have different disciplines working side by side. Over fifty years we have developed an expertise in connecting and integrating the right disciplines, at the right time, in the right way to achieve success for our clients.
Mechanical Engineering
Interaction Design
Design Research & Planning
Software Engineering
Prototyping
Electronic Engineering
Human Factors & Usability
Industrial Design
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Our role in your innovation
Delivering complex transport projects Transportation design projects are typically complex and multifaceted. They will require the careful management of multiple stakeholder and supplier relationships to deliver the best project outcomes efficiently. No single aspect of the project can be addressed in isolation. DCA’s multi-disciplinary team can tackle all project aspects concurrently, delivering a complete transport design and development service within a controlled project management structure built upon many years’ experience of successful project delivery.
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Testing, Validation and approvals
Stakeholder requirements and delightes
Rigs, mockups and prototypes
Research
Functionality, Reliability, Robustness
Communication and PR Visualisation and VR
Engineering
Smart and Connected
Delivering your transport design project successfully
Brand values and Creativity Design
Electronics and Software
Attractive finishes and Appropriate materials
Inclusive and Intuitive solutions fitted to people Human Factors
CMF
Comfortable and Welcoming Ergonomics
Production ready DFMA
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Design solutions for rail
Rail projects are by their nature large scale and highly public. This was particularly true of Hitachi’s Class 800/801 trains for the Intercity Express Programme (IEP).
Published on 12th July 2016 Originally published in Modern Railways
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IEP involves the creation of a fleet of 122 trains to run on the East Coast and Great Western Main Lines at a cost of £5.7bn, replacing Sir Kenneth Grange’siconic design for the InterCity 125. It couldn’t be more high profile! They also typically involve a large number of stakeholders, each with their own, often conflicting, unique specifications. The IEP stakeholder groups include Agility Trains, Hitachi’s immediate customer; Virgin Trains East Coast and Great Western Railway, the two operating companies; the Department for
Transport, who placed the order and defined the specification for IEP; drivers’ bodies, staff representatives and passenger groups, including special interest groups such as cyclists, wheelchair users and visually impaired representatives. The management of such stakeholder complexity created a challenge in its own right on top of the delivery of the actual design solution. The key to success was clear, open and honest communication through all stages of the project. From the outset, four separate review groups were established with membership drawn from all the project stakeholders to represent the interests of drivers, staff and passengers, as well as an interior style review group.
Hitachi Rail Europe Class 800 series First class train interior
Each milestone was focused on tangible deliverables to provide a focus for stakeholder input into the interior design process.
DCA developed a detailed plan for the project, identifying a series of engagement milestones and review meetings for each review group. Each milestone was focused on tangible deliverables to provide a focus for stakeholder input into the interior design process. For example, at the start of the project the interior style team attended a visual brand language (VBL) workshop facilitated by DCA staff. This workshop identified the key IEP interior themes as trustworthy, modern and considerate, from which we developed and documented a comprehensive VBL plan. This identified how these core values would be translated and balanced visually in each of the train interior areas. We then set about developing and illustrating three alternative design concepts that aligned with the VBL plan approved by the interior style review group. One preferred concept was identified by the group and developed into a detailed 3D CAD model. This
formed the basis for a series of interior computer renderings, which were again assessed against the original VBL plan and approved by the review group. Alongside these computer based activities, we worked closely with Hitachi’s manufacturing team in Japan and potential suppliers to establish a colour, materials and finishes (CMF) register. This included sourcing physical samples that the review group were able to approve alongside the computer rendered images. In parallel with the interior style review group’s work, the drivers’ review group moved from benchmarking visits to existing cabs, through computer based ergonomics and sightlineassessments to 3D CAD modelling and computer rendered images. The desk layout was developed jointly and interactively with drivers from both operating companies. The process started with basic cardboard models of the desk and re-locatable paper print outs of the displays, controls 23
Hitachi Rail Europe Class 800 series Toilet modules
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Staff representatives Cleaners Maintenance staff Train drivers Train crew
D Passenger Groups Commuters Cyclists Families Mobility impaired users Tourists
and other desk equipment, then moved through ergonomic rigs of increasing fidelity to arrive at a fully representativeinterior and exterior mock-up of the cab. The drivers’ review group was actively engaged every step of the way, through to a detailed task analysis and glare study on the final cab mock up. Both the other review groups were engaged in corresponding interactive development and review streams focusing specifically on potential staff and passenger issues. Ultimately, the complete interior design was captured and demonstrated in a full size 30m interior mock up designed and constructed by DCA in our large build workshop facility, which all four groups were able to review in detail, as indeed was the NOBO for the project ahead of formal design approval.
Europe were awarded the Human Factors and Ergonomics Society (HFES) Stanley H. Caplan UserCentred Product Design Award 2015 for the interior design of the Class 800/801 train, the first time that an international candidate had won this US-based award. More significantly, Hitachi chose DCA again as their interior design partner on the subsequent Class 385 project for Abellio ScotRail. In this case, the stakeholder structure was far more straightforward, but our guiding principles of open communications and jointly negotiated and agreed design solutions served us well again. This delivered a design that Hitachi is comfortable to deliver and support in service, and Abellio ScotRail is happy to operate; together providing a better journey experience for customers in Scotland.
The success of this multistakeholder process and the quality of its outcome was recognised in October 2015 when DCA and Hitachi Rail 25
Research and Strategy
Our researchers use a variety of tools and techniques to study and understand people’s journey experiences, and to develop an in-depth knowledge of the working practices and needs of operating and maintenance staff. We are looking for evidence to establish what your stakeholders really value, what works well for them, what frustrates them and what excites them. The resulting insights provide clarity and direction for our design team. Most importantly, research enables you to manage and reduce your development risk because innovation effort and development investment can be focused in those areas where our research findings show that it will have the most impact.
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Human Factors and Usability
Transportation projects are about people. Nowhere are the ergonomic demands more challenging or more diverse, ranging from the macro ergonomic issues of passenger flow and capacity to the detailing of individual touch points. Our designs must delight, provide comfort and be intuitive in everyday operation. They must deliver safety and reassurance at moments of crisis. We need to cater for special needs groups, and help operating staff deliver excellent levels of service. At the start of a project, we integrate the ergonomic requirements from all relevant regulations and standards with best practice methodologies to create a comprehensive human factors specification. Our human factors specialists then combine theoretical tools such as task analysis and error analysis with anthropometric data and practical rig based techniques to assess the developing design solutions against this specification, making the human element a central part of our design process.
Computer based assessments of 2D geometry are used initially to ensure that even the earliest concepts take account of the physical environment and usability issues. Close and continual collaboration with the design and engineering team throughout the project ensures that opportunities for enhancing the ergonomic aspects of the design are identified and acted upon. This helps us optimise transport environments for the humans that inhabit them, while at the same time maximising the performance of the wider system. Our work in this area frequently culminates in a formal ergonomic report demonstrating regulatory and contractual compliance.
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Dan Jenkins explains the development of the Hitachi Class 800/801 train – part of the Intercity Express Programme Inclusive design
Article by Dr D. Jenkins Research Lead Human Factors and Usability Published in The Ergonomist 11th November 2014 30
Inclusive design involves designing products so they are capable of being used by as many people as possible, regardless of their size or physical ability. Often very subtle design changes can have a profound impact on the usability of the product for some members of the public, and make the difference between a task being achievable or not. For public transport, inclusive design is of clear importance. For those with very specific mobility requirements, such as wheelchair users, the design can completely remove a barrier to entry. For others, subtle differences in the arrangement and layout of the train can be enough to provide increased independence through the confidence to be able to travel safely and comfortably. Inclusive design has been at the heart of the design of the new Hitachi Class 800/801train – part of the Intercity Express Programme*. Developing a more inclusive train for passengers involves designing a
train that can be used by as wide a range of the population as possible. The design needs to account for reduced mobility (e.g. wheelchair users and passengers with difficulty walking) as well as sensory impairments (e.g. visually impaired passengers) to ensure the train is not only accessible, but also provides its users with independence. For drivers, an emphasis is placed on optimising task performance. This involves creating a comfortable, controlled environment that allows drivers to remain focused and respond quickly and correctly to unexpected events. Approach As with all design projects, the cost of design change increases significantly as the project approaches the final build phase. Accordingly, it was important that opportunities to optimise the design of the class 800/801 train were identified and addressed as early in the design process as possible. The Human Factors work that helped to inform
The passenger areas of a train should be designed so that they provide a safe, accessible and welcoming environment. some of that design optimisation can be summarised into seven core stages: 1. a review of all relevant standards and guidelines relating to human requirements and performance (e.g. PRM TSI, TSI, LOC & PAS TSI, Group standards, contractual documents) to extract key requirements 2. the development of additional requirements based on analysis of the train user population 3. a desk-based assessment of initial train design using 2D drawings and 3D CAD models 4. the design, build and evaluation of low fidelity mock ups (spatial arrangements based on card and paper) 5. evaluation of full scale ergonomic mock ups (dimensionally accurate low fidelity finish) 6. evaluation of high fidelity full sized model (representative fit and finish) 7. documentation of compliance. Passenger areas The passenger areas of a train should be designed so that they provide a safe, accessible and welcoming environment. This includes the saloon areas as well as the more dedicated interior spaces such as the toilets, bike storage and luggage stacks. At the most basic level, inclusive train design involves considering the movement about the train. This involves factoring in the door arrangements, the location of handrails and handholds and the spacing of seats. Colour, material and finish (CMF) also has a clear role to play. Contrast between adjacent surfaces is crucial for allowing those with visual impairments to locate doors, and their controls, and safely navigate step thresholds as well as safety critical elements such as handholds and emergency
call buttons. The way information is presented is also of clear importance, particularly where the ability to read English text is certainly not guaranteed. From a practical perspective, the Technical Standard for Persons with Reduced Mobility (PRM TSI) provides useful guidance to ensure that the design meets the requirements of a wide range of the population. Fortuitously for those designing trains, much of this guidance is clearly defined and measurable (e.g. toilet door controls shall be between 800-1200m above floor level). Elements of the design that are objectively defined in this manner can be readily assessed using drawings and CAD models. For other more subjective requirements (e.g. ability to wash hands from toilet seat), conclusive demonstration using a drawing is more challenging. These requirements are often better demonstrated with a full- sized mock-up of the train which could be explored by a wide range of users and stakeholders. In the case of the Class 800/801 project, this included a wide range of passenger representatives, such as cyclists groups, passengers with visual impairments, and wheelchair users. Mock- up based assessments (spatial ergonomic mock-up and high fidelity mock-up) were conducted to evaluate all aspects of train usage, including the suitability of the luggage provision and ensuring that bikes could be efficiently moved from the platform to the storage area. Feedback was also sought from staff representatives and unions. Additional evaluations of the mockup assessed the ease of moving through the train with a catering trolley, and the ease of locating and accessing emergency equipment. 31
Driver's cab Inclusive design is also critical for the design of the train cab. While the user population for train drivers differs from that of the general public (e.g. there is no requirement to accommodate drivers in a wheelchair), the population remains relatively diverse. From a physical perspective, this involves explicitly designing for drivers ranging from 1514mm tall (just under 5 foot) to 1869mm (6 foot 2 inches). The layout of a train cab is critically related to driver performance. At a basic physical level, train drivers need to be able to view primary controls and displays alongside a clear external view of the track ahead – regardless of their stature. These controls also need to be within a comfortable reach. On a cognitive level, drivers need to be able to quickly locate the correct control in order to respond to unfolding events. Accordingly, 32
the cab control layout needs to consider frequency of use, functional grouping (e.g. all engine controls in one location), left or right hand bias (most the time the left hand will be on the combined power brake controller) and the risk of inadvertent operation. Early low-fidelity mock-ups, constructed from card with stick on controls, were indispensable in engaging train drivers in the cab design process. Workshops with train drivers allowed cab layouts to be rapidly iterated so that they met user expectations while increasing functional grouping and the sequences of frequent tasks. Result Contrary to the beliefs of some, inclusive design is not about designing products for disabled people. Inclusive design is simply good design, as it is design that considers all of its end users. Taking the example of the Universal
Access Toilet, the brief was not to design a toilet for disabled users. Rather, the requirement to make the toilet accessible to wheelchair users was considered in addition to other requirements for creating a pleasant and hygienic environment. The true integration of the inclusive design requirements has been key to the success of this project. By integrating these requirements early it was possible to arrive upon a balanced design without the appearance of bolt on mobility aids. Some of the personal highlights of the project came from working with passenger representatives. The importance of the work was made clear upon hearing a 15-year old wheel chair user describe how he loved the layout of the universal access toilet as demonstrated in an ergonomic mock-up as, unlike many other toilets he was used to, he would be able to use the toilet alone without the assistance of his parents.
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Hitachi Rail Europe Class 800 series high speed train Standard and First class interiors Usability and HF Mechanical engineering Industrial design Visual brand language Prototyping Testing and evaluation Production support Interior design
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Hitachi Rail Europe Class 800 series high speed train Driver's cab Usability and HF Mechanical engineering Industrial design Interior design Prototyping Testing and evaluation Production support
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Hitachi Rail Europe Class 800 series high speed train Toilet modules Usability and HF Mechanical engineering Industrial design Interior design Prototyping Testing and evaluation Production support
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Industrial Design
Successful transport design solutions must be inspirational, exciting and memorable. They have to capture the public’s imagination as well as meeting passengers’ true needs and desires. To create concepts that go far beyond what is currently on offer, our design teams continually question and refine their ideas so that our designs represent a real step forward.
We leverage innovation and creativity to align form and function to deliver a memorable travel experience that passengers will want to repeat time and time again.
Through our work with world-class brands, we have developed a deep understanding of visual identity and a strong appreciation of brand values. We work with brand owners to shift their expectations, push boundaries and help them break into new territories with the ultimate aim of improving brand engagement.
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Colour, Material and Finish
We continually work with material suppliers and regularly attend trade shows, exhibitions and conferences to source exciting material samples for inspiration. Combinations of materials are tested, evaluated and refined to establish what really creates the right visual impression. This allows us to curate palettes of materials that bring travel experiences to life, building upon your brand’s qualities and aspirations. We work with the world’s leading manufacturers and processors, approvals bodies and test houses to develop, refine and implement certifiable material combinations that are fit for purpose and will continue to look great and function well in the travel environment.
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This means we can not only recommend the right CMF strategy, but also how this strategy can be implemented and controlled through production and maintained in use.
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Singapore Airlines First class interiors Seat concept designs Design research Usability and HF Mechanical engineering Industrial design Visual brand language
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Virtual Reality and Visualisation
Generating photorealistic renderings, animations and virtual reality (VR) experiences throughout the design process provides the project stakeholders with a highly accessible and engaging view of how a design is developing. We are working with the latest Oculus and HTC Vive platforms to visualise rendered 3D CAD environments as personal virtual reality experiences. Users can explore the proposed design in VR and gain a real sense of how they will interact with it, even during the relatively early stages of development.
Incorporating VR technology intelligently into a development programme can improve the detailed understanding and assessment of the design before mock ups are built. This in turn can mean fewer physical mock ups and fewer mock up modifications are required.
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Virtual Reality - a new perspective on design Design looks set to enter the virtual world, particularly the design of transportation interiors. The exciting opportunities that exist when working in a digital environment have come of age with the recent introduction of the second generation of Oculus Rift, the HTC Vive and the Samsung Gear VR, lifting this technology out of the gaming arena and positioning it to deliver real commercial value on transportation interior development programmes. The promise of VR is set to change the way we present ideas and accelerate the design process, reducing the time from inception to physical reality. Article by Paul Rutter Senior Associate Published on 23rd February 2017 56
As we develop our ideas using three dimensional computer models we can bring them to life in a way that can draw a far wider range of stakeholders into the design process much earlier than is currently possible.
The quality of virtual presentations allows us to immerse ourselves and other project stakeholders in our designs and engage in a way that, until now, required a full size mock up. The beauty of a virtual presentation is the ability to see colour, form and size as it will be in the final design without committing to physical prototypes. In our latest interior design projects, we are introducing VR into the design process right at the start. By creating VR environments to represent a range of design alternatives, especially for different interior layouts, colour schemes, fabrics and lighting arrangements, we can encourage stakeholders to fully engage with design decisions at the conceptual phase of the project. We are building on our experience with VR to combine low resolution spatial models and VR to provide an ‘augmented reality’ which will allow
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accurate human factors assessments to be carried out directly in a visually representative environment without committing to the time and expense of a full presentation mock up. The debate over the relative merits of VR compared to mock ups is on going. Traditional model making organisations naturally favour mock ups, while newer technology companies champion VR.
At DCA we have expertise in both fields so we can take a more objective position. We see the two technologies as complementary rather than competitive. Combining their strengths streamlines the design process and delivers better solutions through deeper stakeholder involvement in the early project stages.
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Interaction Design
In an increasingly connected world, the challenges and opportunities for delivering compelling user experiences are greater than they have ever been. Our multidisciplinary approach delivers user interactions across physical and digital platforms that are simple, intuitive and a delight to use, and form an integrated part of your transport service offering.
We explore, develop and evaluate interaction solutions across product, application and service layers in order to address user needs with the correct balance of digital and physical touchpoints.
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Mechanical Engineering
Vision is worth little without execution. DCA’s experienced engineering team means we can drive our designs through to market without compromise - be it on functionality, fitness for purpose, robustness or aesthetic intent. DCA’s engineers work side-by-side with our design team to ensure that while our designs remain true to the original creative intent, they are functional, durable and costeffective. We continually research manufacturing processes, materials and technologies to support these aspirations and ensure we can deliver the experience as designed.
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Percy Lane Products SSL Detrainment System Emergency detrainment steps Usability and HF Mechanical engineering Prototyping Testing and evaluation Production support
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Electronic Engineering
The integration of electronic hardware and software plays an increasingly important role in transportation solutions. Our software and electronics specialists work alongside our mechanical engineers and designers in multidisciplinary teams to deliver complex electro mechanical systems. The challenge with such systems is making them robust, reliable and future proof without over-engineering and introducing unnecessary complexity or cost. Our approach is to balance theory, simulation and
analysis with producing physical test rigs and prototypes at appropriate points in the development cycle to reduce project risk while keeping the development timescales and budget lean.
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Software Engineering
At DCA, the software and the hardware designs are developed and cross-checked in tandem to ensure a smooth migration to the final hardware solution as it becomes available. The ever-increasing ability to connect systems and devices together is presenting new challenges, as well as creating entirely new service opportunities. Understanding how smart devices can interact securely with each other is the key to successfully adding connectivity to transport products, systems and services.
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Working closely with our user experience team, we can create proof-of-concept Apps and websites in parallel with the electronics hardware and embedded software.
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UK-NSI Mini Instrument pack Odometer and CANbus communication software coding Software
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Severn Lamb Harrisons Cave Barbados Electric people mover Mechanical engineering Industrial design Production support
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Prototyping and Evaluation
In-house models and mock ups We are rare amongst design consultancies in being able to build scale models, large ergonomic rigs and full size visual mock ups in-house using our own model making team. This gives us unrivalled levels of flexibility, responsiveness and control during the production of your models, rigs, prototypes and mock ups. And this is backed up by the experience, skill and attention to detail of our dedicated workshop team.
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Hitachi Rail Europe Class 385 commuter train for Abellio ScotRail Standard and First Class interiors Usability and HF Mechanical Engineering Industrial Design Interior Design Prototyping Production Support
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Hitachi Rail Europe Class 385 commuter train for Abellio ScotRail Central gangway driver’s cab Usability and HF Industrial Design Interior Design Prototyping Testing and evaluation Production Support
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B/E Aerospace Premium Business Class seating Customer demonstrator for Aircraft Interiors Expo Usability and HF Mechanical engineering Industrial design Interior design Prototyping Testing and evaluation
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CAF C4K train for Northern Ireland Railways Passenger interiors and cab exterior livery Industrial design Colour, material and finish Interior design Livery design
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Westinghouse Platform screen doors for Jubilee line Industrial design Colour, material and finish Interior design Visualisation and animation Engineering Production support
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Xiamen Golden Dragon Navigator luxury coach Coach interior Industrial design Usability and HF Mechanical engineering Visual brand language Colour, material and finish Testing and evaluation Production support Research
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Bombardier Transportation M6 double deck train for SNCB Interior layout and design of double deck passenger saloons Design research Usability and HF Industrial design Colour, material and finish Interior design Prototyping Testing and evaluation Production support
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Singapore Airlines Business Class interiors Seat concept designs Design research Usability and HF Mechanical engineering Industrial design Visual brand language
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Froude Hoffman Robot Driver Electro-mechanical robot for vehicle testing Mechanical engineering Industrial design Colour, material and finish Production support
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Quantum Seating M100 Range Regional Seat Lightweight Standard Class rail seat Design research Mechanical engineering Industrial design Visual brand language Usability and HF
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Brush and Bombardier Le Shuttle trains for Eurotunnel Driver’s cab, single and double deck vehicle carriages Industrial design Colour, material and finish Interior design Prototyping Exterior styling Usability and HF
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Our Location
We work globally from our campus of offices, studios and workshops in the historic town of Warwick, UK. We are located in the heart of the UK with easy road, rail and air transport links. From Birmingham International Airport Travel time 25 minutes From London Heathrow Airport Travel time 1 hour 30 minutes
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Warwick London
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Helping clients achieve success through great product design.
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Contact
DCA Design International 19 Church Street Warwick UK CV34 4AB T +44 (0) 1926 499461 www.dcatransport.com
Rob Bassil Transport Sector Director rob.bassil@dca-design.com Paul Rutter Transport Sector Manager paul.rutter@dca-design.com Dom Hargreaves Transport Sector Manager dom.hargreaves@dca-design.com Roelof - Paul Kruizinga (RP) Transport Sector Project Manager rp.kruizinga@dca-design.com
www.dca-design.com