BREAKFAST TRAY breakfast tray Gabrielle Patterson s3785730 Design prototyping: GRAP1052
A e s t h e t i c s o f Ta r g e t M a r k e t CHARACTERISTICS - Females aged between 20 and 30
-low to medium socio economic background, with individuals finalising studies and embarking upon careers - In spare time enjoys brunch, visting glareies, and walking in parks - Enjoys brunch, esopecially attractive looking brunch - Live in small apartements or share houses with minimal, contemporary furnished.
R e s e a r c h : t r ays
research: butter dish
research: egg holder
research: spoons
r e s e a r c h : toa s t r ac k
research: knives
r e s e a r c h : wo o d va r i e t i e s
research: techniques
i d e a g e n e r at i o n - i n t i a l s k e tc h e s
i d e a g e n e r at i o n - i n t i a l s k e tc h e s
i d e a g e n e r at i o n - i n t i a l s k e tc h e s
i d e a g e n e r at i o n - P r otot y p e s : t r ay
i d e a g e n e r at i o n - P r otot y p e s : S P O O N H A N D E L S
i d e a g e n e r at i o n - P r otot y p e s : K N I V E S
i d e a g e n e r at i o n - P r otot y p e s : TO S T H O L D E R
REFINEMENT Only one prototype was made for the butter dish as it was chosen straight from the sketch phase as its design worked best with the design of the selected breakfast tray
selected breakfast tray concept.
The prototype for the egg dish and a the salt and pepper dish have been simply constructed fro paper and will be used just for a reference of size through out the refinement phase
R e f i n e m e n t - s K e t e c h e s o f l e gs a n d f i n a l p r otot y p e Prototype for a single leg, layed flat
R e f i n e m e n t - l ayo u t
R e f i n e m e n t - b r e a k fa s t t r ay
REV No. -
REVISION NOTE
DATE
DRAWN
-
-
-
CHECKED -
150
200
ISOMETRIC VIEW
TOP VIEW
15
30
5
W
FRONT VIEW
SIDE VIEW 30
DESIGNED
G PATTERSON DRAWN
PSC
DATE
DWG TITLE
SCALE
PROJECT
20/04/19
GRAP1052-BREAKFAST TRAY
1:2
CHECKED
TOLERANCES LINEAR +/- 0.5mm ANGULAR +/- 0.5° SHEET No. GRAP1052 TECHNOLOGY 4 ALL DIMENSIONS IN MILLIMETRES UNLESS NOTED OTHERWISE. 1 OF
DWG No.
INDUSTRIAL DESIGN
SOLIDWORKS Educational Product. For Instructional Use Only.
6
REVISION
A
TRAY
SHEET SIZE
FILE NAME
1
A3 DIMENSIONING OF TRAY ELEMENTS
REV No. -
REVISION NOTE
DATE
DRAWN
-
-
-
CHECKED -
140
80
15
126
10
80
35
W
12
10
15
TOP VIEW KNIFE
10 TOP VIEW SPOON
DESIGNED
G PATTERSON DRAWN
PSC
DATE
DWG TITLE
SCALE
PROJECT
20/04/19
GRAP1052-BREAKFAST TRAY
1:1
CHECKED
TOLERANCES LINEAR +/- 0.5mm ANGULAR +/- 0.5° SHEET No. GRAP1052 TECHNOLOGY 4 ALL DIMENSIONS IN MILLIMETRES UNLESS NOTED OTHERWISE. 2 OF
DWG No.
INDUSTRIAL DESIGN
SOLIDWORKS Educational Product. For Instructional Use Only.
6
REVISION
A
SPOON AND KNIFE
SHEET SIZE
FILE NAME
2
A3 DIMENSIONING OF TRAY ELEMENTS
REV No. -
REVISION NOTE
DATE
DRAWN
-
-
-
CHECKED -
170
26
9
20
24
31
15
30
W 200 TOP VIEW
260
SIDE VIEW
DESIGNED
G PATTERSON DRAWN
PSC
DATE
DWG TITLE
SCALE
PROJECT
20/04/19
GRAP1052-BREAKFAST TRAY
1:1
CHECKED
TOLERANCES LINEAR +/- 0.5mm ANGULAR +/- 0.5° SHEET No. GRAP1052 TECHNOLOGY 4 ALL DIMENSIONS IN MILLIMETRES UNLESS NOTED OTHERWISE. 3 OF
DWG No.
INDUSTRIAL DESIGN
SOLIDWORKS Educational Product. For Instructional Use Only.
6
REVISION
A
CHAIR LEGS: FLAT
SHEET SIZE
FILE NAME
3
A3 DIMENSIONING OF TRAY ELEMENTS
REV No.
REVISION NOTE
DATE
DRAWN
-
-
-
CHECKED -
18
-
FRONT VIEW DISH
ISOMETRIC VIEW LID
ISOMETRIC VIEW DISH
3 22 43 TOP VIEW LID
40
15
59
W
FRONT VIEW LID
53 50 TOP VIEW DISH
SIDE VIEW LID
DESIGNED
G PATTERSON DRAWN
PSC
DWG TITLE
SCALE
PROJECT
20/04/19
GRAP1052-BREAKFAST TRAY
1:1
CHECKED
TOLERANCES LINEAR +/- 0.5mm ANGULAR +/- 0.5° SHEET No. GRAP1052 TECHNOLOGY 4 ALL DIMENSIONS IN MILLIMETRES UNLESS NOTED OTHERWISE. 4 OF
DWG No.
INDUSTRIAL DESIGN
SOLIDWORKS Educational Product. For Instructional Use Only.
BUTTER DISH AND LID
DATE
6
REVISION
A
SHEET SIZE
FILE NAME
4
A3 DIMENSIONING OF TRAY ELEMENTS
REV No. -
REVISION NOTE
DATE
DRAWN
-
-
-
CHECKED -
35 REAR VIEW BOTTOM VIEW
31
SECTION VIEW DETAIL VIEW DEVELOPMENT VIEW
ISOMETRIC VIEW
DIAMETRIC VIEW
W
TRIAMETRIC VIEW
SIDE VIEW
TOP VIEW
TOP VIEW
35
SIDE VIEW
FRONT VIEW FRONT VIEW
DESIGNED
G PATTERSON DRAWN
PSC
DATE
DWG TITLE
SCALE
PROJECT
20/04/19
GRAP1052-BREAKFAST TRAY
1:1
CHECKED
TOLERANCES LINEAR +/- 0.5mm ANGULAR +/- 0.5° SHEET No. GRAP1052 TECHNOLOGY 4 ALL DIMENSIONS IN MILLIMETRES UNLESS NOTED OTHERWISE. 5 OF
DWG No.
INDUSTRIAL DESIGN
SOLIDWORKS Educational Product. For Instructional Use Only.
6
REVISION
A
EGG HOLDER
SHEET SIZE
FILE NAME
5
A3 DIMENSIONING OF TRAY ELEMENTS
REV No. -
REVISION NOTE
DATE
DRAWN
-
-
-
CHECKED -
230 100
40 50
ISOMETRIC VIEW
W
TOP VIEW
25 25
DESIGNED
G PATTERSON DRAWN
PSC
DATE
DWG TITLE
SCALE
PROJECT
20/04/19
GRAP1052-BREAKFAST TRAY
1:1
CHECKED
TOLERANCES LINEAR +/- 0.5mm ANGULAR +/- 0.5° SHEET No. GRAP1052 TECHNOLOGY 4 ALL DIMENSIONS IN MILLIMETRES UNLESS NOTED OTHERWISE. 6 OF
DWG No.
INDUSTRIAL DESIGN
SOLIDWORKS Educational Product. For Instructional Use Only.
6
REVISION
A
TOAST HOLDER
SHEET SIZE
FILE NAME
6
A3 DIMENSIONING OF TRAY ELEMENTS
The process- knife The Process begun by cutting the rough shape of the knife with a combination of the bandsaw and then a japenese saw once the piece became to small to use safely on the bandsaw.
The handle of the knife also went through a series of sanding from 80 grit sandpaper through to 320 grit. while the premice of the breafast tray aesthetic is geometric, I slightly rounded of the edges of the handle to make for a more comfortable user experience.
To create a the blade on the edge of the knife a series of sanding was completed. I found it benificial to use a spreading motion (as if one was spreading butter onto the sandpaper) and this helped accomplish the refined edge on the complete knife
T h e p r o c e s s - b oa r d The board began by first squaring and leveling the piece of timber using a comvination of the table saw and the planar. to stasbilise the the rig the two template sections were screwed to a backing board and then the piece of timber was held in place with a clamp. With the rig allowing for just the corner pieces of timber to be removed, the whole rig was run through the table saw again with the blade at 30 degrees and the blade hieght at 30mm. The piewas run throught he table saw on both faces and then the timber was rotated to cute each coerner out.
Then is was a matter of contructing a rig for the corners of the wood to sit in to, in order to make the corner cuts. To do this we got a long bit or scrap wood and made the traingle cut through the whole section. thid was done by angling the table saw at 30 degrees and setting the blade hieght to 30mm and running the wood through on both faces to get the angle cut on each side. Then a 90 degree trangle was cut from the centre (cut out section phtographed above) leaving to pieces of the rig the the pievce of timber coul slot between. As shown in the adjacent image.
Finally the corners edegs were sanded out to geta smoothe and clean finish.
T h e p r o c e s s - s a lt a n d p e p p e r d i s h To begin the salkt and peper dish it was important to prpare the mold. This involved making sure it was clean and absent of residue from other peoples castings, after this a spray lubricant was added to mold to stop the resin sticking to the cast. To prepare the resin it involved accuratly measuring equal quantities of part A and part of the solution, as I used the square mold this required 20gm of each part. Then the solution was mixed together, carefully to stop the formation of bubbles
The resin was then poured into the moulds. This was done from a height, which was done to also eliminate any airation that may have occured in the mixing process. The mixture was poured in a slow an steady point at one corner of the the mold. I accidently moved my hand away fromthe single coner and as a result there is a deviation in the base of my dish that i tried to eliminate with sanding, however it is still slightly noticable. If to repeat I would pay extra attention to this pouring process to prevent this inconsistency.
After removing the resin from the mold a series of sanding was conducted using wet sandpaper and applying a small amount of water. I used sandpaper from 600 up to 2000 to achieve a smooth, velvet like finish. The sand paper did leave a light black residue on the dish, so I washed with soapy water and this removed a the majority of it.
The process- Butter dish I began with the lid, which started with making a mould for the vac-former. I lamenated several pieces of ply together and then used a hand saw to cut the the section out of the centre. Then I sanded back the surface to make it as smooth as possible for the vac-former. In retrospect I would not use ply wood as even though the surface was smooth to touch, the vac-former still picked up the layering ridgeds.
To use the vac-former, i inserted the mould and lowered it into the machine and then inserted the piece of plastic and secured it with the metal plate and lock mechanism and then pulled dover the heater. To evaluate if the plastic was at the right temperature I waited until it appeared concave. Then I quickly pushed the heater back, lifted up the mould and pressed the vacuum button.
It was also key to add and angle the sloped in from the bottom edge, as detailed in the bottom left image, as the draft angle allows for the mould to be removed from the plastic. This draft angle was achieved through sanding on the belt sander and by hand.
I had to do this process several times as due to isses with webbing. Once I achieved a succesful product, an oscillating saw was used to cut away the excess material
The process- Butter dish
To finish the lid it was a matter of sanding the base to a flat and even finsh. To carry out the spray up, it was first impoortant to prepare the cans by bringing them to a luke warm temperatur in hot water and then vigarously shaking them. I began with 5-6 coat of the primer filler, sanding with a combination of 320 grit sand paper and steel wool between layers. To make the base of the butter dish it begab by constructing it out of ply. I cut out the pieces in accordance to my dimesions and the lamenated the together. Then it was the process of the spray up, where three adjacent prodcuts; - primer/filler -coloured enamel paint -shine top coat
I then moved onto the coloured layers, again appling 5-6 layers and sanding back between layers. Towards the final coats I only used steel wool as it is more delcate. Lastly I applied 4-5 layers of the gloss top coat, again sanding with steel wool between layers.
The process- spoon The spoon process beagn at the hydraulic press, by sandwhiching a piece of brass between the mould plate, a piece of rubber and metal blocks. After setting up the stack it was a matter of pumping the press until a curvature was achieved
I used finer and finer files as i mover into the more delcate details of the design, and also used a sweeping motion to achieve a smooth edge.
Finally it was the finishing process which consisted of many layers of sanding starting with 320 grit and then moving into the wet sand paper from 600 all the way up to 2000.
Step 2 was marking the handle with a scribe and then using a fine blade in a jewellery saw to cut out the spoon. After this it was a matter of using metal files to file back the edges
After this the dremel was used in combination with a polishing compound to refine the smooth and achieve the high shine finish.
T h e p r o c e s s - Toa s t h o l d e r
I began by making a template and then marking and cutting the piece of acylic to the correct size.
To prepare for sandblasting I marked out the details with masking tape.
Then I took the piece to the sand blasted and applied the sand.
For the bending process it was a matter of resting the acrylic on the bar heater for a few minutes and then bending to the write angle. A few tips that I picked up was to mark out the squared line that is to be heated, using masking tape to ensure it is not bent along a weird angle. Also I found specifically for my centre fold which is quite small, I cut a piece of ply to width between the two faces of the fold which meant I had a wedge to fold the arylic into, that acted as a gauge to ensure I got enough bend.
The process- egg cups To cut the egg cups, there was a special router bit that was inserted into the drill press. I began with a large bit of my timber and marked the centre point of my egg cups. Then it was a matter of turning the drill press on and hollowing out the semi circle. As I used red gum, a hard timber, I had to take this process slow and constantly raise and lowver the router bit to avoid excess heat due to friction. As I got further and further into the cut I had to continuosly lower the rotational speed of the press, to avoid the timber catching.
After routering out the semi-circles it was a matter of cutting down the egg cups to size, which I used a combination of the bandsaw and the japenese saw to accomplish. Finally I sanded the egg cup to a smooth finish, using several stages of sandpaper.
T h e p r o c e s s - l e gs I began the legs by first getting strips cut to 29mm by the gilletine. Then I sanded back and polished the strips, following the same process as done with the spoon.
Then folowing the template and dimentions i used the fine jewellery to cut the legs down to size. then Finished off the edges with the file.
To get the bends in the metal i used a seried of files top create mitres along the bend lines. Then it was a matter of using acombination my hand and my body weight to bend the metal. Unfortunately during the process the top bend became to fragile and snapped off, however I was able to adapt my design quicly and effectily. The 90 degree bends were done using the magnabend folder, to geta non-rudd fold as the fold line would be visable.
With the newly adapted design, the legs somewhat hover, rather that sitting flush in the crevices. To hold the legs in place I used epoxy adhesive.
T h e p r o c e s s - f i n i s h i n g wo o d To finish the wood I first, sanded the wood back using both the orbital sander and hand sanding the smaller details. going through several stages from 80 grit for particulary gnarly section all the way up to a 320 grit to finish.
I also applied the oil to the egg cups and the knife to finishe them off.
Then it was a matter of applyng the oil. I chose a kitchen timber oil as will protect the wood and will also mean it is still food safe which is a key criteria for the purpose of the breakfast tray.
The oil was applied several days before submission to ensure complete absorbance.
I applied two coats, waiting 1 hour between coats to ensure absorbance. With the oil bringing out a righ cherry colour from the wood.
F i n a l O u tco m e
E va luat i o n The completed tray, while slightly differnt to the original plan, is completed and ready for purpose for many mornings to come. Using geomtric shape as the common thread across the various elemenst of the design, ultimatly thue componets purpose as both stand alone objects as as a design collection. There are subtle aspects included in many of the objects, like the butter dish lid with its V shape accomating a piching motion to remove or, the spike at the end of the spoon which allows it to double a fondue fork for one to dip the bread into their hard-boiled egg, with these aspects seeking to nhance the user experience of the design. The legs were the major hurdle when completeing the project and while they have not worked out as intially planned, I very much appreciate how they make the wood like like its somewhat floasting and i believe this helps lift the design from being so ridgid and solid and gives it a bit more femininity which appeals to the target audience. Over the course I have learnt how to use and approach various materials and process and have found the experience both interesting and at times challenging. Ultimatly this has given me insight not only into what materials are available for variouse purposes/fucntion but also how each material is different and therefore how they are appropriate for different things. While I made several failed attempts in this project, and not everything is as perfect as I would like, i.e. i would like the vac-formed lid to be smoother and the spray up to be more even without cracks, I believe if to complete this assignment again, I am equipped and capable of producing a very high quality prototype due to all the lessons I learnt through this process. Overall I am very satified with the breakfast and I look forward to using in the future. I also look forward to implementating the diverse skill set from this project across the variose parts of both my degree and career that are to come.