This card model enables quick visualisation and physical freedom for clients interaction with the stand. The stands’ scale gave me a sense about dimension, and what to develop after understanding the clients.
Top view Front view Side view
The mitred butt joint, dowelled mitre joint and square ended butt jointsupportit.
Design and Technology Design idea 2 CAD / CARD MODELLING / Freehand Sketching
Design process: At each stage, the progression and development is presented step by step, to show how the product would be formed.
The components could loosen or break over time and may be swallowed by children.This is a serious hazard. However, I made a change to how I fit these little components.
I decided to change the round shapes to two sloping intricate shapes. This fits the needs of elder clients.
Red mahogany is a type of wood that will look very attractive for my clients,who have demanded, as well as meeting the ‘materials’on my specification
My main problem came with the idea of heavier headphones not being able to sit on the stand. Now, instructions provided for my clients are read: “stand it sideways for 5 kg items.
To avoid removing the modern and simple and plain colours, I had to make a decision about how many electrical components to add. I chose 1 plug slot and 2 usb ports to ensure flexibility for my clients.
Back view Angled view
The card model here presentsasenseofscale. Thedesignrequiredlevels or set support edges for balance. It was justified that clients’ mobile earphones or lightweight headphones could be supported, but not the heavyloadtype. Front view
Above are three of the perspectives of my CAD model, to emphasize each dimension. Beside this are the two final renders which considers a clients’real, everyday life example scenario.
3D view
Design and Technology Design idea 3 CAD / CARD MODELLING / Freehand Sketching
Had to keep it heavy to withstand the forces of the heavier headphones.
Follows modern theme with the use of simple grey shades and the material aluminium.This is appropriate from my specification and my clients.
cm from spec
Through my spec check, there is a variety of different things this stand checks but asking my clients what extra functions they required for their daily tasks would have been useful.
Allows easy accessibility for my client user.Zinc coating, non toxic finish to give a clean and polished look for my clients. It has curved edges and non sharp vertices to protect my clients’ fingers.
Dowelled
Design Process
This continues the development by incorporating a stem and a full size plug that is useful for clients and their charging
These are the front, side and back views of my product. These cad models helped me to achieve an ideal aesthetically pleasing product. A problem I solved during this process was finding the perfect headphone sit located here. I was finding simple shapes like squares, rectangles or triangles for the support but they were lacking style; balance.
To overcome this, I had used the idea of a horse saddle that had a similar shape to this. It fits the needs of the specification and the requirements of my clients Beside this you can see this idea.
Modelling
I created various type of lamp shades using cardboard, hardened clay and balsa sticks to test lighting effects. The purpose of this project was for me to understand and see how light sources deflected and bounced of different types of designs.
These are part of the “JOIN-iT” project we did at the workshop, to get a hands-on experience with timber and a variety tools.
My first joint was the finger joint, which was the strongest joint.
My second joint was the mitre joint, which are usually used to make picture frames. It needs to be cut at 45 degree angles.
Wood joints
1. Measuring tools we used: tri-square, steel ruler, pencil to mark, block of wood.
2. Cutting tools we used were the tenon saw, junior hacksaw, coping saw, laser cutter, pillar drill and the battery drill.
My third was the housing joint.This simple slot cut into a piece of wood helped to increase - the glue area.This was done using a router, and it works very well in MDF. Acommon example is in shelving.
Here is another project I did, called the G.O.D project. It is a plywood pencil box with a custom lid I added to represent Hong Kong and the G.O.D.
3. Smoothing: Tools like the Second cut file, glass paper, belt/disc sander, line smoother for acrylic and sand paper.
Box & lid
Practise Cuts with set square
Skills demonstration
chair
SHOES
CastingProject
Vacuum Forming
CriterionA: Mindmap, Research Plan, Design specification
In the current situation, various environmental issues have become of utter importance in helping us designers to rethink the way we tackle wider scale issues. Global warming, climate change, ocean acidification, pollution, landfills and acid rain are all significant issues. Hong Kong has a highly dense population accumulating approximately 8 million. 5.2 million plastic bottles are thrown away daily, which weigh 136 tonnes. In Hong Kong, plastic waste is a major threat to our aquatic environment.
It is essential that we dispose of plastics into recycle bins, instead of the ocean, where 6,000 of our marine species are at risk. Key findings from research reports that a majority of Hong Kong’s plastics being collected for recycling being sent to recycling plants in China. Only a small percentage of this is locally recycled. This leads to problems like air pollution, landfills and ocean acidification. By creating a final product for my project, I aim to create a solution that prevents filament being affected by users sensitive to low frequency UV light. By identifying the design goal, target client and constraints, I will spread awareness about plastic waste to promote sustainability
Design goal (Expected outcome)
Design brief
To design and create a product that protects filament from UV light.
Target Clients (Middle-income) teachers, students and enthusiasts that require 3D printing facilities.
Target market Users in segment interested in long-lasting, simple-to-use and cost-effective products
Design criteria
1.Costs of materials are low.
2.Drivers for invention including desire-to-help.
Product feasibility and scale of production (SOP)
Rapid expansion in the market for environmentally-friendly, low-energy-sustaining and aesthetically-pleasing.
The potential of 3D printers has allowed 20% of manufacturing concepts to form final-products. Being printed layer-by-layer in subsequent cross-section stacks, allowing additive-manufacturing-operations to be performed without huge, high-throughput machinery.
Limitations include high-filament-costs. To tackle this, utilizing recycled plastic brings large cost-saving potential. However, it requires specialised research-and-development of reconditioning polymers.
Plastics come in various forms: natural, synthetic and bakelite. Being derived from crude-oil, various combinations are created in fractionating towers to create long-chain thermoplastics like ABS, PLA and PTFE, which are viable examples to reduce UV exposure.The graph below shows the solid waste in metric tons per day for various plastics.
Major constraints Limited time, tools, materials, working parts and various technological compromises.
Appearance
1.1 Product should be conscious of environment and accessibility. Focusing on auditory and visual feedback
1.2 The product should feel light and smooth.
1.3Avoid using sharp edges, instead use curved edges.
2.1 Materials should cost about a ¼ of the budget.
(Customer)
3.1 The design should appeal to teachers, students & enthusiasts.
1. Target Market
Amodern, balanced minimalist product with a smooth quality finish
This product has round edges to allow for safe interaction
Overall aim is HKD$50 and materials range between $10-12
3D printer Introductions increased for educational purposes in Hong Kong.
3.2 Should look modern and appealing. Targeting late majority and laggards demographic (students and teachers)
3.3 Should fit in their lifestyle. Drivers for invention, such as constructive discontent or technical curiosity
4.1 Manufacturers aiming to reduce plastic filament waste.
4.2 Most extra materials should be reused or recycled.
During growth phases, challenges like reducing plastic filament waste arise
Any extra leftovers are to be recycled or reused again.
4.3 My Product should avoid the moisture exposure It takes technological approaches compared to competitors in the market.
4.4 Ikea desks on average measure 60 cm wide.
4.5 Automated system with smart measuring technology
Quantity (size)
Through process innovation, anti-uv tech tackles problems for specific environments.
Through smart measuring technology, the automated system calculates filament allocation.
5.1 Should be 70x200mm, 2-3kg and in batch production. The average maximum sizes for the best balance and portability
6.1 Signage encouraging PLAuse Sound feedback is used to communicate and support target users.
7.1 Raise awareness to community about plastic My product will be endorsed to advertise and raise awareness.
7.2 Reduce amount of plastic wasted The product tackles high UV environments like Hong Kong.
8.1 JITproduction for mass manufacturing
Materials should be easily transportable and also protected from moisture. 9.1 Manufactured for disassembly
1.1. Product is aimed at eco-fans -Eco fans as they show concern for the environment
1.2 Product aimed at ages from 12-60-I chose this range because my clients meet this range
2.1 People at least within middle-class-Allows higher price ranges with higher income earners.
2.2 Learners like teachers, students, manufacturers and enthusiasts. -Typically find these groups of people working in studio spaces
2.3 The product has affordable prices for target users -Users prefer such products at price $50 Hong Kong dollars.
3.1 The material prices are appropriate-Anti-uv layer and supporting dome that surrounds filament costs approximately $10-$20.
3.2 Form and Function -Form follows function: the product functions as an anti-uv layer
4.1 The product should satisfy the users needs -The product must be a replacement for whole disposable plastic cases.
3.3 Convenience -Users prefer simple, quick-to-use dispenser-style cases that are easily operated. 2. Target audience 4. User needs 3. Market analysis
4.2 Needs to follow FSC certification to be eco-friendly -FSC certification will ensure safe and ethical methods of forestry .
5.1 The product must be able to be able to compete in a market against the conventional casing products
-Conventional case products follow the same dimensions and have a similar form.
5.2 Product has to be unique -The styles are the only thing that differentiate each case
5.3 Innovative, contemporary and a highly desired product
5.4 The product solution must have aesthetic qualities
-Convincing consumers to change requires innovation to disrupt the market
-Research suggests other solutions aimed at solving similar problems exist.
5.5 It must be designed for pleasure and emotion -The product acts as an ideo-pleasure from being eco-friendly
5.6 It will require to be competitive: cost-plus pricing
-The addition of a percentage of cost added to total
Wheels (x2)
Fixed pivot point inner-piece is aluminium for toughness
Filament reel made of PLA(gives off non - toxic Lacticide)
Exploring new forms , shapes and styles.
Sloping at an angle of 45 degrees for the reel
Case has two rotary mechanisms between to support sliding close.
Different wooden materials such as a hardwood shell, a mahogany backplate and inside pine/cedar softwood Filament reel base
Design Idea 2
Card model 2
Using magnets to hold up the reels securely.
Rate Idea6 /53/5
Aportable box-shaped design
Possible use of PLA, PTFE or aluminum.
Rate CAD6 /5 3/5
Cut extruder mechanism for the reels
Infinity sign-shaped for two reels at a time.
MODEL6 - CARD/PAPER HYBRID
Portable box shape Access to reel from the top.
Aluminium base
Pastel colours that are made of Polyethyleneterephthalate glycol-modified.
1. Use Masking tape to define an edge
2. Use a NET not individual pieces
3. Use a Stanley knife not scissors
Could improve on the sizing and proportion Filament mechanism will use a screw Reel body for the filament to go on.
4. Use a cutting mat
5. Use a safety rule
6. Keep Fingers away/behind from blade
Design Development of Idea 2
By analysing the specification check table, I’ve decided to further develop design ideas 2 as it’s best for my target user group needs as well as being very practical
This prototype shows the use of ABS and PTFE plastics.
Manufacturing Process Type
-low printer and material costs for completing complex printing jobs
-Easy to operate and fast compared to SLA and SLS
- Printing flexibility
-Effective for rapid prototyping
Justification for choice related to specification
The detailed development was first chosen from the six design ideas, and then tested and developed.
This design meets the requirements of 1.1 and 1.2 as it focuses on auditory and visual feedback which in turn is complementary to the modern and balanced minimalist feel. It also meets 2.1 and 3.2 because the price fits a HKD$50 and materials range between $10-12. This means that the late majority and laggards will be appealed.
Additionally, the design is flat-pack meaning it can be easily removed and replaced or recycled. This suggests to me and my target users that it fits the criteria of 4.2 and 4.2 as during growth phases, reducing plastic filament waste will not become as much of a challenge. The extra leftovers can be recycled or reused again. The use of technological approaches are competitive in the market.
Furthermore, the size on average is appropriate as according to 4.4 and 5.1 the process innovation and anti-uv tech tackles problems for the specific environments, while the average maximum sizes is 70x200mm for the best balance and portability.
I made use of signage, social media and various product advertising techniques in order to achieve 6.1 and 7.1. Sound feedback on the Amazon website can be used to communicate and support target users. It endorses plastic recycling and this in turn will help me to obtain 7.2 tackles high UV environments like Hong Kong. For 8.1/9.1/9.2: With JIT, our product ships by Amazon quickly through high quality, efficient safe transport and reliable quality control for best productivity.
Overall, the strengths are with product safety and of environmental hazards. The weaknesses are to do with uncertainty about quality control.
-Low print resolution
-Low print quality
-Slower compared to injection moulding, -Support structure requires removal tools
-Poor surface quality and requires finishing
-Possible environmental /ventilation needs
- Cheap 3D printing method
-High print resolution for an excellent finish quality
-Support structure quickly removed and printing has flexibility
- Versatile material choices and also compatible with variety of materials
Selective Laser Sintering (SLS)
-Medium print resolution
-Printed parts have excellent mechanical properties
-No need support structure
-Processing and printing flexibility
-Extremely fast compared to 3D printing
-No support or finishing structure required
- Extremely low cost per production unit
-Suited for mass manufacture
Being able to print complex-shapes at low costs with moderate-quality.
-Prints may degrade if any sort of UV light exposed
-More expensive and slower than FDM
-Requires post-curing, but may be automated
It can alter designs between prints ; obtained from SLA& SLS
-Low finish quality
-Expensive due to the high printer costs
Prototyping process for testing components showed satisfactory quality of prints
Superior printing quality and lack of need for extra ventilation
SLAis slower and costs twice as much as FDM counterparts.
Affordability in the final product is essential, making FDM justifiable.
These printers are more expensive by a large margin.
-Compared to SLAand FDM, SLS printing limited in size
A small amount of material would be saved using SLS
-Limited in complexity of shapes
-Extremely high initial cost, high printer costs
injection molding limited in prototyping, compared to previous printing techniques.
-Designs cannot be revised
-Not suited for prototyping
However, its capacity to print at high speeds and low average costs makes it suited for mass manufacture.
Fused Deposition Material Printing (FDM)
Stereolithograph y Printing (SLA)
Injection molding
Justifies the choice of appropriate materials, components, manufacturing technique and processes.
-
-Laser is accurate
-Prints dxf files
-quick
Laser can damage users eye if they don't wear goggles
Significant quality difference compared to FDM.
-More detailed
-More precise
Although laser accurately prints CAD, looking inside → danger to user.
Long time to print even small items E.g 6-12 Uses photosensitive resin, vertically-moving platforms, and hardening resin to print.
-Decreased development time, costly mistakes and increased number of variants. Important steps can be omitted problems overlooked Unsuited for large-sizes
-Drill for Spruce
-Allows casing to achieve desired joint-look -mitre-joint -Less workers required in a CNC/CAM work environment → less-productivity
Heated extrusion nozzle that moves through the x and y-axis
Process of component parts: 1 - 4,
Part 1: Lower case
This case structure is the main body that will be using the plastic abs/polytetrafluoroethylene to be protected by blockers, stabilisers or absorbers in order to achieve the anti-UV solution that helps the user who is going to use the product,safelysustainitlonger.
Part 2: Top closure
This top closure will be also built with abs/polytetrafluoroethylene. It is round in order to give the reel thatwillbeinsidespacetositinside thefullconnectedstructure.
Part 3: Spool rig
The filament requires a case to support its body. I have created a spool case that has adjustability optionswiththeaidofthelockand screwmechanismIhaveadded.
Drilling holes: rotating bits through materials → held together → won’t move.
CNC
-Accurate cuts
-High quality finishes
-Fine details
-Minimal distortion Equipment costs are expensive ; Special training/skills is required Where a material is reduced into desired shape through machinery.
Part 4: lock and screw
The round core lock mechanism in black and green is made out of aluminium and includes a green aestheticpieceinordertohelpwith thevisibilitywhenscrewingitin.The screw is available in one size and can be adjusted when connected withthelockmechanism.
Part 5: Cylinder
This is an attachment piece that needs to be connected in between thespoolrigwhenassembling.
Approximatecost:$250
Advantages DisadvantagesJustification
Aluminium is a lightweight, ductile & malleable material.
Aluminium properties: electrical conductivity, corrosion resistant & is easily recycled.
Main problem with this material is it’s expensive.
When cut, sharp and unsafe edges become apparent to user.
Non-ferrs metl is useful with useful properties for my product.
Allows my product to be long-lasting, but difficult to buy-in-bulk.
itemQtyPart#Material
21Left/ right ring
ABS
High-carbon steel is a tough tool and a smooth material.
It can be used to shape materials and is recyclable.
Approximatecost:$400
Approximatecost:$325
Approximatecost:$120
High impactAS is a versatile, low cost and impact resistant material.
An aesthetic product and has insulation and dimensional stability
ABS (Acrylonitrile-Butadienstyre ne) is tough, has high-impact-strength and wide colour options.
It’s scratch resistant, lightweight, durable and has a good chemical-resistance.
PTFE is effectively a flexible,rigid synthetic plastic polymer.
It has high hardness, is a good insulator or is flexible when soft.
Main problem is that it needs to be heat treated.
Can rust unlike aluminium if not protected e.g paint.
Can become brittle and is subject to being flammable.
Susceptible to UV degradation ; has poor chemical resistance
Main problem with polymer is its potentially undesirable glossy finish.
These finishes must come with its high quality injection moulded processes.
High cost materials and is soft and fragile, which is disadvantageous.
Shape can change with pressure.
This ferrous metal requires heat treating processes, which are expensive.
Expert or specialist machinery is required. Hence, availability is scarce.
Rubber in HIPS: A durable-thermoplastic
high-impact-resistance, that softens when heat-treated
Similar to aluminium,ABS has useful properties for my product.
itemQtyPart #Material
Glossy finish may distract with reflections ; extraction process is expensive.
Properties allow good insulation, non reactivity and it is non-toxic.
will be useful for the bridging components as it can be flexible in weight.
Overall, my research gives me a detailed breakdown of the final shortlist process I will require to make my final product
is the
I will require after carrying out the manufacturing processes.
itemQtyPart #Material
11ScrewABS
Part 4
itemQtyPart #Material
11CaseABS
Measurements and Bill of materials/components
As this product will be situated permanently indoors,ABS will be an effective lightweight, colorful option that can be recycled after use. 2
While this product may be situated indoors, the PTFE material will help to to resist the direct UV degradation if taken outdoors or during assembly 3
consistently and accurately is by the left. The CAD diagram presents the main aluminium board, with two 10 x 30 cm slabs which each contain four nuts or bolts of. These will be dowel joints that are drilled down carefully using safety goggles and precaution. On top of each slab are circular slabs with a radius of 14 cm cut down to allow for the cylinder to screw through both circular slabs. Finally, I will be locking it in place using custom 4-1/2 and 5-1/2 screw kits to hold it.
Below are the final chosen methods of finishing for each of the individual FDM components for the product.
ExplanationAdvantage Disadvantage
Using grit sandpaper to sand down the ABS plastic. 1. It smooths the irregular surfaces.
First medium grit. Then use fine sandpaper to remove stepping-lines
2. It can control exactly how smooth the surface is.
At same time it increases roughness, to produce smooth finish.
3. Only 1 printed prototype sanded
Sanding it down 4. Sanding method is safe and efficient.
Use a buffing wheel made of cotton or wool.
5. Sanding removes scratches on the first and second grade.
1.ABS smooth and shiny
1. There may be Incomplete layers seen.
2. Overdoing sanding may ruin the product.
3. Sharp areas difficult to reach or uneven sanding.
4. Prototype will not be able to mimic mass produced.
5. Machines can be dangerous
1.Dipping ABS into it gets messy. Layering can be inconsistent.
The vapour penetrates throughABS filament.
2. Final product has professional, modern quality-look, as required in specification.
2. Takes long time for the fumes to penetrateABS.
1. Complete final CAD models in Fusion 360 Laptop 12 hoursReview all dimensions for each model and their tolerances.
Save regularly to prevent data loss ; work in well-ventilated areas.
2. Export CAD models → STL
Laptop Short 5 minuteEnsure the file name is clear and accurate before printing.
Save-in-file to prevent data-loss. Check file is in “STL” format.
3. Open STLfiles in Ultimaker Cura for printing preparation
4. Print files on 3D Printer
Laptop, google drive, USB Stick, 3D Printer
30 minutesCheck: accurate scale, orientation, materials and file type , before saving
Ensure data saved and 3D printer is ready for print-job.
Value stream mapping
5. Remove components from 3D Printer
6. Remove support structure, excess material and sand down surfaces
7. Inspect prototype for defects; repeat all steps if needed
Ultimaker 3D Printer 15-30 hours (depending on no. of printers in use)
Monitor the printing process regularly. Check there’s no format error.
Tie-back loose-hair, remove accessories which may get caught with printer.
Gloves if necessary 5 minutesRemove components gently to avoid damaging the components or printer.
2 hoursEnsure support structure traces removed ; surface sanded-down uniformly and evenly.
Allow printer-components to cool-down. Ensure printer completed process before removal.Avoid hand burning.
Handle equipment and sharp-edges carefully ; Dispose sharp-parts of pieces immediately. May need safety goggles/gloves.
I will conduct a survey to evaluate the effectiveness of my filament case product, a solution to reducing plastic waste. I had a classmate who fits in my target market. He complied to participated in using the product. I had conducted a verbal questionnaire for qualitative data. I asked a range of questions to help me identify the price range and usability
The first question was essential for me to identify out of the four users, how many have seen an identical type of product. From the results, I found that there is a large proportion who suggested to me that they have seen a similar product, but they do believe that the anti uv surface finish feature is a unique feature that they have never seen before. This possibly suggests to me that my product can compete in the market.
My result indicate to me that it was 50/50 in terms of what stood out from my product. On the one hand, my products’ shape was a unique feature that was identified. However, I was given feedback from one of my clients about how the form of the product looks similar to various other products, This is one type of improvement that I will make for my final product.
Question 2 gave me an idea about first impressions of my clients viewing the product. They were able to build a better understanding of my product after seeing a demonstration on how it functions. By allowing them to test the product and its functions, It was highlighted how the product was simple, intuitive and fun to use.
I conducted a user trial to evaluate the effectiveness of my filament case product. a solution to reducing plastic waste. I am testing with a target Design and Technology student user. He complied to participate in the test I conducted; a verbal questionnaire for qualitative data. I asked a range of questions to help me identify the price range and usability.
User1
Q1. What do you think is unique about this product?
This question helped me to identify whether my client has seen a similar product. He said that although the form looks similar to a tissue roll box, he saw the advantages of this specific form when having seen the plastic filament inside the container. He said that most filament cases he has seen have been either exposed to the UV or very slightly hidden, but never fully supported and enclosed.Therefore, this indicated that my product could be potentially competitive compared to other similar products in this manner.
Q2. How did you feel about the product after using it?
Question 3 suggested to me that while 75% of the target users would use this product at their studio spaces, their is still 25% of users that will not. This suggests to me that while the need for my product is promising, it is possible that some of my target users may not see the anti-UV feature as essential or as a change they are ready for.
By giving my client some time to get a feel for the product and inspect it all around, I asked about his experience using the product. He said that it felt quite smooth to the touch, not sharp due to te round corners and he also highlighted how the mechanism was quite simple.This was quite promising as I aimed to create such a product that was simple to use. He did however say he couldn’t immediately afford what it did because there are a wide variety of functions that this product could serve if it was sold in the market. For example, for toiletry purposes or maybe sewing. Taking this away, I hope to improve the intuitive purposes of my product.
Q3. Would you use this product at your home studio?
By giving my user a chance to place the filament inside and test it with the 3D printers at our workshop, he explained how simple and logical the product seemed when placed into context.As a user who owns a 3D printer at his home, he said that he would definitely try it because as one who is experienced with filament plastics, he knows how in the long term filament polymers can absorb the UV and its energy can excite protons, causing degradation.This is him speaking from his own experience.
From conducting the research and user trials, my target users have helped me to identify certain areas such as presentation for improvement. I have further identified areas within the product that I feel don’t fulfill the design criteria.
Adjustments to design based on feedback and evaluation against design specification
DesignAdjustments
The users from my questionnaire and trial also commented on the functionality of the product. Users suggested that the product could maximise its potential if it didn’t use as much plastic material and waste itt. This could be fixed by making the product even more modular. This would require making each component into a single piece attachable piece that can be easily decomposed. Even though this would increase the amount of tools used, in mass production this wouldn’t be a big challenge as economies of scale will be applied, and the overall unit cost would decrease as more components are made.
Users from the interview suggested a thicker cylinder could be utilised to support the reel case and balance its weight. This was improved in order to give a greater fidelity and definity for my product to fit into various studio environments. As the part is made of PTFE, I have been able to integrate this into the new flat-pack style reel case.
Ergonomics and Function
To improve ergonomics for the filament extruder, the circular hole at the top would need to be increased to allow more sizes of filaments to be placed through it when printing.The holes would also need to be bigger so the user wouldn’t have to ‘claw’the product when holding it from the top. This should help make the product more accessible and more adjustable.
Continuation of Design adjustments.
The reel case can be placed in both the vertical and horizontal orientations. This is an users to be able to find the most convenient position according to their setups. I also have tested using order to see first, if it fits, and second if the filament can be extruded through the top nozzle hole. The flat-pack style is essential because it means the user can take each piece apart one-by-one in order to assemble or disassemble it.
One of my initial ideas was to make the product modular. On the left is an image that presents the idea of a modular component by component case. I believe that if I apply this concept to my product, it would be more feasible and successful as it would fulfill the design brief and achieve all the needs in my target market.
Size/Volume
The product can be adjusted if certain things such as creating a slider with the cylinder secure lock. This can help to scale down the dimensions for certain reels.This would make it easier for the users to use their own filament.The design can also be changed to so that it is thinner and less bulky.This will make the product even more lightweight, ending up with a smaller mass/volume and amount of materials needed.
Graphic Design
Even though this wasn’t mentioned in the interview or survey, the product could include some graphic designs instead of offering plain solid colours. This would make the product even more unique amongst the market as no other competitor has done this. This would also be more appealing to users that are loyal to other brands as the only colours available are solid.
Criterion E: Commercial Production: Appropriate choice of materials and components for commercial production For commercial production, I aim to create a modular, flat-pack style component that requires materials which I have identified with reference from my research. Plastic materials was considered carefully due to safety reasons and for changing the way plastics harm the environment. I was provided feedback about how useful and advantageous the form of the reel case model is. Plastics are derived from natural materials which are created by bonding molecules together. Hence, for commercial manufacture, the polymers I will be considering for commercial production will be PTFE, high impact PS, and ABS The reasons why I have chosen these three is due to their recyclability, durability, cost, aesthetics, machinability, ability to be manipulate and maintain shape, and their resistance to impact,
Advantages Disadvantages
-Versatile
-High flexibility
-Thermal, electric and chemical resistant
-High density
-Versatile
-Low-cost
-Impact-resistant
-Good aesthetics, insulation and dimensional stability
- Fabricate
-Low-cost
-Good-resistance to impact
-Strong and stiff
-Heat-resistant
-Maintainability
-Easy-to-paint
-High cost
-Shape can change with pressure
-Soft and fragile
Justification
Properties allow good insulation, non reactivity and it is non-toxic.
PTFE will be useful for the bridging components as it can be flexible in weight.
-Brittle
-Flammable
-Susceptible to UV degradation
-Poor chemical resistance
-Glossy finish
-Low melting point
-Needs addition to resist UV exposure
Rubber in HIPS: A durable-thermoplastic + high-impact-resistance, that softens when heat-treated
Criterion E: Commercial Production
Appropriate choice of manufacturing techniques appropriate for commercial production
The manufacturing technique was identified through the information from the video “Fused Deposition Modeling (FDM)Technology’, I firstly look at this is a commercial production.
3D-printing application: My chosen method for various colour customisation options.
By prototyping, I found thatABS and PTFE will be the most appropriate options for my components.
Components
Advantages
-PTFE for the cylinder bridge-connector is useful as it’s high-density.
-It has a flexible body that allows for moving versatility.
-Can be printed individually
-Standard size
DisadvantagesJustification
-The case is set in size
The addition of the extrusion hole/PTFE cylinder is essential
-This may mean that reels aren’t able to fit properly
-Standard components separate from printing are available alternatively
-It can be removed for maintenance -Printing such components may be a waste of material/money.
This helps to provide durability and ease its support
Adding this part is costly, but creates an innovative product.
This allows it to reach the market and create positive-change.
Advantages
-Lays off material layers down quickly
-Plastic sent to nozzle that can turn flow on/off
-Nozzles can be heated to melt material, making it accurate.
-Nozzles can precisely move in both x-y directions by CAM.
Disadvantages Justification
-Process isn’t as repeatable/may fail to replicate real product
This rapid prototyping is great at decreasing development times
-Very time consumingImportant development-steps may be omitted to produce quick, cheap-working models.
-High costs
Costly mistakes and increasing product complexity
-High Power ConsumptionThese challenges need to be overlooked.
I chose this method because it is a layer additive manufacturing process. By using thermoplastic materials to make both end-use parts and prototypes, this technology has a high accuracy and excellent strength-to-weight ratio for prototyping.
FDM process first ‘slices’3D CAD data into layers
Data transferred to machine constructs the part through a layer-by-layer process upon a build platform. Thin filament spools of thermoplastic are needed to create the cross-sections of parts.
Uncoiled material is slowly extruded through heated nozzles, which lay down both support and thermoplastic material upon preceding layers.
Build platform moves down while nozzles continue creating layers though x, y and z.
To instruct the 3D printer on how to print each of the individual components from my filament reel design, I had to convert my fusion 360 file into G code file. The G code is a computer language that provides instructions for a piece of machinery.
High impact PS
For commercial production I will be using FDM, a 3D printing rapid prototyping process. I chose this due to the following:
Firstly, I chose Fused deposition modelling because it’s faster and cheaper in the long run (due to economies of scale) which makes it most appropriate. As my product is aimed at a wide range of users that have access to 3D printers, the supply of my product components has to be able to keep up with demand. This means either the manufacturing speeds have to be significantly faster than other methods like stereolithography or my product CAD files can be published on online retail markets like Amazon. This allows for my product to be sold through a variety of methods. This is further supported by the fact that printing my product takes between 3-9 hours.
The second reason why I chose FDM is due to the quality of the surface finish. Because FDM a quick layer by layer printing process, this results in the addition of the surface finish looking and feeling smooth. This is a huge advantage in mass manufacturing because this will make improve quality assurance and reduce the reliance on quality control. However, their is the limitations of having supervision for the printing.
Thirdly, FDM is the most appropriate due to the complex shapes that can be easily printed. Because my product has a lot of complex components to print both in the inside and outside, it would allow the wall section to be reduced to about 1.5mm.
Also, the product may need to be adjusted in size to allow my customers reel to fit. Hence, I will allow for customization of sizing using CAD to modify it. It can be possible for a thinner or thicker wall section to be adjusted. If my product is affected by heat, the plastic may warp and cause unwanted rough surface finishes. I would include a ribbing structure in my product to help reduce the heat, however it is unnecessary to do this as it would increase costs due to the increase in the plastic used.
Part Image
Base backplate
[Stitchlinesandfillets]
Reel slot inside case
[Bleed+draftangle]
Case head
[Stitchpattern]
Overall, FDM is the most appropriate method of manufacturing because it is much faster and cheaper in the long run. Even though start up costs will be expensive due to the machines, it would still be cheaper as the online retailing option becomes available, making costs per unit to gradually decrease as more units are produced
Section of body [Wallsection]
Modifications
Producing the shell of the base itself will not be difficult. It may be suitable for large scale production, but, in order to increase the quality of the product for commercial sales, I would create a base model version that is made out of aluminium sheet.
The standard component here is the reel slot. This can be an optional part of my product if being bought on the online retail sites. It is one that is made out of two solid circular pieces and joined by a cylinder that slots through each of the two pieces. I will add a adjustable slider between the two parts to allow more reels to fit.
This piece may become unstable over time as a single piece to slot onto the base of the body. Therefore, I will add an option for a detachable clip that locks one side of the head onto the body. This will create the opportunity of a lever motion that will be useful to allow it to lock-in place.
In order to be more precise with the fittings of the reel-slot inside the whole body, I have taken a section cut in order to understand the limits and the tolerances. I found that the margin for error is approximately 5-10mm, and so using an alternative to the ABS plastic for the reel body may be a more maintainable and stable option. In order to do so, acrylic or plexiglass may be the most appropriate alternative due to the incredible strength, stiffness and optical clarity that is available in it.
The quality of the surface finish is also relatively high because the layer by layer process would create a smooth touch. Because my product has a wall section that is thin enough, I would not need to add ribbing structure as the wall section is thick enough to withstand heat damage.
Section of inner plate
[Ribbingandcuttingline]
Any electronic components that are wired throughout the inner plate are going to require soldering work, which can be quite time consuming. While my product will not direct have any electronic components due to the purpose of it being sold as a case, I test my product using various wiring routes and researched different types of wiring strategies employed on this product.Through doing this, I was able to find a size that was correct.
Measurements and Bill of materials/components
As this product will be situated permanently indoors,ABS will be an effective lightweight, colorful option that can be recycled after use. 2
While this product may be situated indoors, the PTFE material will help to to resist the direct UV degradation if taken outdoors or during assembly 3
As this product will be situated permanently indoors, this versatile and impact resistant material provides an attractive aesthetic that provides insulation.
that are
The components that will be needed are going to be sourced online and the FDM costs will be
through a
As
Scales of production methods include prototype, custom, batch and continuous. Prototypes, one-off and custom are those using different materials to commercially produce and machine. These machines are not advanced, like moulding machines or dye techniques. Furthermore, custom production is making a one-off perfect, unique item like a wedding cake. Batch production is an inexpensive, limited production run. Continuous production is one thing made all the time.
Each of the costs are based on statistics that are from factories in Hong Kong and China. As workers need to be on maintenance duty for a set number of hours, calculations are based on how many hours 50 workers could work and how many units could be produced in 1 week. FDM has a cycle between 3 hours to 12 hours. My fixed costs are filament as they stay the same and variable costs are for maintenance and printing. I plan to sell each unit at HKD$80 as price was suggested as feedback from my surveys. Material costs for ABS, PTFE and PS add up to $525.
Batch production will be chosen as it is a balanced, cost-effective manufacturing method that process in batches. The flexible labour allows it to create customisable parts, creating greater choice. While products have to be stored, increasing costs, flexible labour allows efficient creation of components of the product in various seasons or markets.
The workforce is at about 50 workers currently.At the start, we will try to break even by focusing on having a smaller workforce, which would make my product more feasible as it wouldn’t have even hit the market yet. Additionally, I would consider lowering the price by HKD$10-$20 in order to win market share against competition such as Soval store who sells their reel products at about HKD$59. My calculations don’t take into account the law of diminishing returns and this is one of the limitations in China, due to a lot of workers working over time. My calculations do not take into account the costs for every additional unit that is produced and how my costs will be affected if so. For my pricing strategies, I will sell my product at HKD$79.99 in order to attract user attention. This is one of the strategies used by other successful brands such as Soval store, as it helps to make the product seem more cost effective. The price of $79.99 is about half of the competition because my product will need to sell quickly in order to gain market share quickly. By decreasing it down to $51.99 after a few weeks, my product will be competitive enough to go against new brands and so I will be able to outsource out in South Asia and beyond. This because these are where low income households are and my product includes targeted users within this class. By sourcing the components and investigating costs.These manufacturing costs will be essential for calculating profit.
Marketing strategies: I will be using the 4 P’s of marketing to identify a suitable strategy
Pricing strategyDescriptionEvaluation
Cost-pluspricing A strategy that is the addition of a certain percentage of the cost being added towards the total cost of a reel product.
This is required as it is a pricing that includes direct material costs or labour costs which are added to the overhead costs. This is suitable as it is a competitive strategy that covers the variable costs/profits
Product $
This strategy always ensures a profit margin exists and covers all operating costs, past the break even point, incentivising the manufacturer to continue. Hence the profit would be made around 50% of the costs, making HKD250.
Break even = FC/(Price - VC)
The tool is designed to help calculate “actual” costs + profits generated from a 3D printed part. The calculator slices the STLfile and estimates values needed to calculate cost of print.
Using the FDM price estimator, I calculated the cost of each part components and then found the cost of the materials used to createABS. This would add to the fixed costs, found from the table shown above and the variable costs shown in the above screenshots.
Promotion is a major process in the commercial manufacture stages. It enables us to make our target audience aware of the reel case product. For my product, I will be advertising the recyclable and sustainable plastic usage and informing them on the price of the product. By informing about the benefits, I will strive to encourage them to purchase the sustainably promoted product my product, they will be eco-friendly, they will enhance a sense of ideo-pleasure product (primary demand) will essentially be influenced. Through this I can increase sales increase market share in terms of recycling aid products. Overall, by promoting, I will increase awareness of the existence of the product in the market. There are three main promotional strategies which I can use to make people aware about my product depending on the market sectors; geographical, eco-status (values), age, and market segments;
1.Above the line: Internet marketingThis promotes awareness and is important when first entering the market 2.Below the line: Branding - product packaging ; Sales promotion - (Buy 1, get second product for half price) These will help me to get my marketing messages across to my target market as well as be competitive in the market.
A3 Primary Research
Material: Plastic (rods and the base of stand)
Initially, the product looked accessible,simple and easy to use at the start. The purpose of the product was clear, it serves the purpose of supporting headphones that were being sold in this shop. Far back, it didn’t seem to be scratched.
Theme: Modern
I tested the functionalit y and it was able to easily hold the lighter headphone s.This product is also portable.
I visited Fortress for my research to analyse similar products in the category. I felt the shape of them, how heavy the products were and observe their features.[access fm]
Material: Steel (long edge), rubber (short ,wide edge on top) and aluminium (base of stand)
This product felt quite evenly shaped.The base of the product fits quite well with the design and I thought this was more of a unique shape compared to the previous product.The theme is modern.
Materials: Glass/plastic, half for protecting the advertisement sign and other half for adding an extension such as an edge to allow placement of product. It’s accessible, specific to one headphone product with black/cyan colours only as well as wider
The colour was greyish-white throughout the whole product. The shape itself isn’t interesting, and the whole product looks too simple or plain; a bit boring for my target market.
The face of the cylindrical-shaped rod felt smooth, it was easy to handle ,thin and light in shape.
This thin plastic base felt quite lightweight, suggesting it could easily break.
The cost of this product is HKD$15 which is cost effective.To maintain it, you need to be aware of
scratch
The rubber acts as a soft, protective cover for the headphones.
Aluminium material in the base felt quite cold from the touch and made me feel a little uncomfortable.
This thin, stiff and long steel piece is well polished. It has a smooth finish that is noticeable and it sets the modern feel that heavier headphones can be placed on. This is another unique, simple but creative way of showcasing the actual headphones on the stand.This plastic/glass material uses more than half the space to advertise, while the other to present the headphones.
Could potentiall y break
Fits with modern theme
Base of the produc t (thick layer)
ProductAnatomy
To help me understand size, weight and the shape of my headphone stand product, I will first be measuring out different areas of my personal headphone product that complements my stand.
Width: 2.4cm
Height: 7.5 cm
Length: 0.4 cm
Length: 15cm
After taking all the different measurements , I have also collected accurate measurements done by my product’s manufacturing website.
7.29 x 2.92 x 9.81 inches
0.27584086 kg
Length from outer left side of cup to outer right side of the cushion:5.2 cm
Length: 11cm
Width: 2.8 cm
Height: 1 cm
Length: 19 cm
Height: 5.5 cm
Width: 5.5 cm
Casing width: 0.7 cm
Height from top of the cushion to the bottom: 9.5 cm
Primary user investigation (survey)
In order for me to understand what my product should be aiming to look like, I have created a general survey with a whole variety of questions relating to size, function, aesthetics, dimension and I sent it out to a wide range of daily consumers.The data I collect from these consumers will help me to learn and have a better understanding from what the people generally want in a product like a headphone stand.
Finally I’ll be able to decide what I should implement or avoid adding into my product, and how to sell the product so that people in the market can see more benefits of my product in their lives.
The purpose of this multiple choice question was to understand the acceptable price range that the consumers found suitable. Majority was 66.7%, and they chose that between HKD$50 - $100 was a suitable price for them. Now I know how much consumers are willing to pay for this product, and It might increase if they demand for extra accessories in it.
In terms of style and aesthetics, this question provides a variety of options.The pie chart above presents that the majority: 44.4% of people are looking for a modern, simple and clean finish.This clearly shows that the modern look of my product is desired by a higher percentage of consumers. In terms of designing, I will explore recent modern designs from the market to help capture the parts and create my final design, which should appeal to many consumers and have a high demand like most other headphone stands.
Material choice is important because it decides the base of the product or rather the body section of my product which will be the first thing that stands out to consumers looking for this product. I believe consumers are looking for this product with good durability, long lasting qualities, something that won’t break so easily if it dropped on the floor or just something that has proper functionality. With high demand for wood, I’ll look to provide information soon about how I will sustainably and environmentally get wooden materials that can be properly broken down for re-use later.
