Industrial Design Portfolio

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INDUSTRIAL DESIGN

JOSHUA FERCHAUD 2018

CONTENTS

04-17 : SURVIVAL FOR ALL - UST BRANDS SURVIVAL AID

18-27 : SOFTENING THE JUNGLE - CHILDREN’S DISCOVERY MUSEUM SEATING

28-35 : EMOTIONAL DURABILITY - HEIRLOOM CAST IRON

36-43 : ARTISTIC COMFORT - ERGONOMIC HAND TOOL

44-49 : EAMES 670 - CAD COMPLEX SURFACING

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UST BRANDS SURVIVAL FOR ALL

Create a product for UST to help in an extreme emergency. No one left behind.

THE STORY A PEACE OF MIND

UST Brands designs survival tools and kits. They have recently acquired a technology company and are looking to broaden their current product offerings.

Earthquakes, floods, tornadoes and mudslides can happen at any time. Current market offering for these events are typically simple to use but may require lots of additional space for storage.

I aimed towards something that could be compact or concealed. An item that is ready to be used at any time necessary.

I started by following typical UST Brands products. I started with a key chain lanyard, a pocket knife-communications device and a kit that can double as a splint.

The refinement encompassed varying disasters. Including gaining access to fresh water, generating electricity and access to portable shelters.

IT’S IN THE DETAILS INSPIRED BY UST PRODUCT

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PERSONA

MEET WILL

Male - 27 years old.

6’0” - 205 lbs.

Born with Type-1 Diabetes.

Very athletic - Certified Crossfit Trainer. Has had multiple eye surgeries due to diabetes complications (eyesight continues to be an issue..

Carries bulky kit for consistent testing and injections.

“I have a pretty busy schedule. I compete in many different competitions in preparation for Crossfit and Tough Mudder, but no matter how often I travel, I am always worried about forgetting my [insulin] kit.”

CROSSFITER DIABETIC TRAVELER

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SCENARIO

CONCEPTS

I attempted many carriers for the insulin. I wanted the carrier to be practical and portable. I also wanted the device to be easy to use; therefore, I designed a blood glucose monitor that would snap on the wrist.

Diabetic kits vary in size from small to large but even the smallest of kits can be burdensome to a diabetic. I noticed that there were no first aid kits for diabetics to use if they were trapped in a location where they did not have access to their insulin.

REFINEMENT

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I designed a compressible 4ml insulin injector to be inserted into a device.

MOCK UPS GRASPING SCALE

I wanted a simple shape that is reminiscent of first aid kit but without the typical rectangular shape. I sought after multiple shapes that will seem as though they belong within the same design family.

The blue circle is the universal symbol for diabetes. The glossy aluminum shell coupled with the blue circle allows the diabetic persons to fell a sense of comfort in case they forgot their insulin at home.

The result became a first aid kit with sharper, angled edges to represent a diamond. It is something that has a high durability appearance..

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THE SOLUTION THE KIT

The kit contains 6 monitors, 6 vials of insulin on one side. The other contains typical first aid supplies for up to 20 people.

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SOFTENING THE JUNGLE BRINGING NATURE TO THE CITY

Develop social furniture for the amphitheater of the San Jose Children’s Discovery Museum

THE CLIENT

CHILDREN’S DISCOVERY MUSEUM

The Children’s Discovery Museum wanted to have “social seating that would act as a gateway from the concrete jungle (amphitheater) and bring the natural feel of Bill’s Back Yard.”

Bill’s Back Yard is a natural space for children to play, build and explore. Whereas, the amphitheater area felt cold and unused.

The CDM really wanted nature to be incorporated into their amphitheater. So initially, I just drew down some concepts that would either a) be a learning experience or b) just be beautiful. Either way, both tied in nature in one shape or form.

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IDEATION

REFINEMENT

Inspired by Bill’s Back Yard, I came up with some concepts around edible gardens, log seating, and modular play areas.

The amphitheater has a large black walnut tree in the center and the CDM expressed their passion for the Guadalupe River. It was these two objects that inspired me to create a river resin seat.

At first I wanted to make the seat out of concrete with wooden legs and a pigmented resin running through it. This proved to be much to heavy and too brittle.

I wanted to explore various methods for the folding chair. The chair with the silver brackets was an option that is possible, easily manufactured and safe, the framed chair above felt more artsy and not as safe, the chair to the right was the extreme option. It contains kerfs to allow the wood to bend. This is the direction I chose to pursue.

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FINAL DIRECTION
This chair is visually pleasing and unique. It would be a social focal point for the amphitheater.

CHANGING DIRECTIONS

THE FOLD UP KERF AND RESIN POURING

Making many kerf cuts allows the wood to bend smoothly. However, black walnut is a very hard wood. Bending the wood caused many cracks and eventually it broke. I learned that I could fill one side of the kerfed wood with silicone rubber. This gave it some support while not allowing it to bend too far.

The next step was to learn how to pour resin and get a quality color scheme to represent a river. I pour many different colors, some with metallics, some with solid colors and some with both. Doing this allowed me to get the pour I wanted.

I poured two more times to test metallic and non-metallic pigments. I also decided to add a glow in the dark powder into the resin. The image on the far right was the final pour into a solid piece of live-edge black walnut.

After the resin pour, I planed the wood, glued it together with biscuit joints and then added the kerf cuts in the middle section so the seat could fold up.

Once the kerf cuts were made, I attempted to fold the part into seated position; however, the black walnut was too brittle and the kerfs shattered. This led me down a different path.

I utilized the existing kerfs to act as a lumbar support and then used Soss hinges to hide the bend.

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NEW TECHNIQUES

The final design is a beautiful product that can act as a chair when there is overflow from the cafe in the museum or as a barrier to guide and direct people during events or activities.

The nature of the resin river allows the children to make their own river by lining multiple chairs side by side.

18.00 38.63 6.50 0.06 0.44 6.00 16.12 3.00 1.65 11.54 0.75 0.95 22.36 Kerfs hidden to show legs Resin pour varies based on live edge
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EMOTIONAL DURABILITY DESIGNED TO LAST

Create a product worth keeping that has an inherent emotional value.

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WHAT IS EMOTIONAL DURABILITY?

Most products are temporary products. The question to solve is: How can I create a product worth keeping for generations?

Emotionally durable products are objects that customers want to keep for a lifetime and invoke an emotion. A table scratched by your first dog, a baseball glove passed down from your grandfather or book given by a friend.

In my case, my family has been passing cast iron skillets down for at least 100 years. When I use my iron skillets I always reminisce on my grandpa’s southern cooking, our family camping trips and the lessons on cooking and maintaining the cast iron for years to come.

After exploring different methods for the handle to connect, I combined the ease of use of a slide button with an under-hook to give the user full control of the skillet while the handle is attached.

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HOW IT WORKS

Ergonomic handle allows for comfort through all ages. The skillets comes with a salt and pepper holder that also acts as a location to keep the handle when not in use.

Pull back on button. Insert through the handle. Push down and release handle to lock.

The removable handle solves the issue of requiring a separate towel, cloth or special glove when grabbing a cast iron skillet.

The bocote wood handle with a cast iron sleeve ensures that it will last for many generations.

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ARTISTIC COMFORT ERGONOMIC FORM STUDY

Re-design a soldering iron for a specific function - stained glass artworking.

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PERSONA

MEET DAN

Male - 54 years old

Occupation - Civil Engineer

Education - Chico State

Family - Wife and 3 Children

“I think that a good soldering iron should be balanced. It should just rest in the hand.”

“I would like to be able to hold [the soldering iron] in many different ways. My hands tend to cramp when I am soldering for long periods of time.”

CRAFTING HUNTING STAINED GLASS

DEFINING THE PROBLEM COMMON ISSUES AND DESIRES

Stations are too expensive

Adjustable temperature is great but not on the soldering iron itself

Too small of area to hold on too

Limited ways to hold the soldering iron comfortably Cord sometimes becomes tangled

Behaviors:

Simple movements, soldering iron is in hand for a maximum of 2-5 minutes.

Returns iron to stand, applies liquid flux and repeats.

Goals:

Comfortable enough to use so he can use it after long days of work.

Multiple ways of holding iron.

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IDEATION

I combined the aspects of the separate forms to further explore in the mockup phase.

With my sketch ideation I was not only thinking about form, but also about how the tool would be used and stored.

Once the shape was determined, I aimed at developing an aesthetically pleasing and ergonomic head for the soldering iron.

I developed mockups utilizing the straight wrist principle and numbers from ’The Measure of Man and Woman’ by Alvin R. Tilley. The body forms were given to many different users to determine which shape was the best fit.

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The angle of the tip is so the hand is further away from the heat and the work space is more visible.

Rubber around the whole iron allows for comfort at any angle. The on / off toggle is located in the rear away from the hand.

This design allows for at least four different ways to hold the soldering iron. Each of which keeps the wrist straight and the hand relaxed.

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EAMES 670 LOUNGE SOLIDWORKS SURFACING

Utilize SolidWorks surfacing features to create a complex assembly representing a designer chair.

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UNDERSTANDING IT’S IN THE DETAILS

I was inspired by “the warm, receptive look of a well-used first baseman’s mitt” that Ray and Charles Eames’ were aiming for with their 670 Lounge. I found an authentic Herman Miller Eames 670 Lounge at Pivot in San Jose.

I took multiple measurements of all the aspects of the Eames’ Lounge and then I re-created the chair in SolidWorks.

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