Ingrain- A study on Materials and Processes

Advanced Materials and Processes jozy klupar

The Man Art gallery owner Well established in the art world and has a wealthy family

Collector Fine art books films

sINGLE SOCIALITE mid thirties

creative sophisticated intelligent tech-savey

The space eclectic collection

of unique expensive items

Art gallery

large space to entertain guests

The problem

He needs speakers that CAN effectively deliver high quality sound throughout his entire space WITHOUT LOOKING OUT OF PLACE. iT MUST FIT HIS UNIQUE STYLE AND COULD BE USED IN HIS ART GALLERY OR IN HIS HOME.

NEEDS tHE CORDS MUST NOT BE VISIBLE mUST HAVE THE OPTION TO PLUG IN A DEVICE MUST HAVE HIGH VOLUME, HIGH QUALITY SOUND that can fill a large room MUST look sophisticated & expensive

Research

Satellite Speakers Small speakers with either a single driver or a tweeter and midrange only. They rely on a subwoofer to reproduce low frequencies.

Floor Standing Speakers Also known as tower speakers, these larger, full-range speakers typically use multiple drivers to reproduce a wider range of frequencies and improved bass response.

Bookshelf Speakers Better suited to handle higher power output and bass than satellite speakers, these speakers come in small to mediumsized cabinets.

Speakers determine the overall sound quality of your system. The most important factors in choosing a speaker are personal preference, speaker type and the stereo components you will use to power your speakers.

Different types of speakers include satellite speakers, bookshelf speakers, floor standing speakers, built in speakers, center channel speakers, portable speakers and subwoofers.

Portable Speakers This speaker is small and can easily be transported.

It produces a higher frequency meaning it cannot hit lower frequency notes..

Center Channel Speakers This speaker is designed specifically for the center channel, should sonically match the other front speakers, and usually sits on top or below a TV set.

Built In Speakers In- and on-wall and inand on-ceiling speakers are mounted on drywall or other surfaces to create a custom-installed look.

Flat Pannel Speakers Thin Flat Panel Speaker that delivers excellent sound

Research

FLat panel speakers (above) & ceiling hanging speakers (below) Podium Sound, a Cambridge UK concern, have released a new pair of flat speakers for the high-end audiophile market. Although we’ve found flat-panel speakers to sound “thin” at best in the past, the Podium 1 speakers reportedly deliver excellent sound. The sound emanates from both the front and back of the panels, unlike conventional speakers. Also engineers at Warwick University. created this amazingly thin speaker. Dubbed the FFL (flat, flexible loudspeaker), it looks like tin foil but reportedly delivers a clear, crisp sound. These speakers range any where from $11 - $1500.

decorative Opportunity

Plain

hang on wall

hang from ceiling

opportunity FLat panel speakers combined with ceiling hanging speakers

By hanging the flat panel speaker from the ceiling it allows for one of the most innovative features of the flat panel to become useful, sound is emitted from both sides of the speaker. This allows for sound to reach places in a room it could not reach before and creates a louder fuller sound. the speaker would be wireless and Stream from an iPhone, iPod, iPad, or other Apple Bluetooth enabled devices.

Ideation

Mobile Concept This concept has the flat panel suspended between frame.

wood & fabric Concept This concept uses wood and fabric to create an interesting appearance.

bent wood Concept This concept uses a flexible flat panel speaker to fit ibetween the bent wood.

inspiration

Final Direction

Materials study Low Volume

Polished Aluminium and Brushed Bronze Machined or cast

Pine and Red Mahogany machined

Persian walnut, English walnut wood Heartwood can range from a lighter pale brown to a dark chocolate brown with darker brown streaks. Color can sometimes have a gray, purple, or reddish cast. English Walnut is rated as moderately durable in terms of decay resistance and has a moderate texture. .

Reasons for choosing English Walnut *local vendor *aesthetic quality and “curly appearance *expensive and rare usually only seen in veneer *good sound quality- acoustic properties *connection to musical instruments Vendor: California Hardwood Producers 1980 Grass Valley Highway, Aubrun CA 530888-8191

Material Study High Volume

Polypropylene Matte grey Injection Molded

Polypropylene glossy Black injection molded

Polypropylene glossy Bue injection molded

Arboform

or liquid wood injection molded

Lingin (an often-discarded element of regular wood) is combined with natural resins, flax and fibers that can be injected into molds and form extremely complex, precisionshaped objects normally made of conventional, nonbiodegradable petroleum-based plastics.

Reasons for choosing Arboform *Unique material *aesthetic quality Vendor: Tecnaro Germany Telefon: (0049) 7062 / 917 89 02 E-Mail: info@TECNARO.de

BOM low volume

Part Name Body -part 1 -part 2 Outline -outline 1 1.2 -outline 2 -outline 3 Speaker holder Speaker cover Speaker Total Tooling Part Speaker & OEM Total Retail Price Ratio

1 10,000 400 200 10,600 $3000 .3

Quantity

Material

1 1

Dark Walnut Dark Walnut

2

Aluminium sheet

2 4 2 1 1

“ “ PP knit fabric Flat Panel Speaker 10 1,000 400 200 1,600 $3000 1.9

4 gauge

Process

Size

Weight

Finish

Tooling cost

Part cost

CNC Machined CNC Machined

31.5” x 10” x 1.5” 31.5” x 13” x 1.5”

8 lbs 8 lbs

polished polished

0 0

175 175

Lasercut

31.5” x .5” x .12” 3” x .5” x .12” 10” x .8” x .12” 8” x 6” x .12” 2.75” R x 22.5” 30.5” x 22” x 3.25” 28.5” x 20” x 1.5”

1 lbs .065 lbs .4 lbs .2 lbs .5 lbs .025 lbs 10 lbs

“ “ “ “

0

25 3 10 7 3 2 200 $400

“ “ Extrusion cut and sewn

r 50 200 400 200 800 $3000 3.75

100 100 400 200 700 $3000 4.3

1,000 10 400 200 610 $3000 4.9

5,000 4 400 200 604 $3000 5

10,000 2 400 200 602 $3000 5

black

10,000 0

Retail Price $3000 Optimum volume Around 75 cost to make $750 Due to the large size of the parts each unit would be sold for $3000. This can be easily justified because

High part cost Low- no tooling cost

of the materials used. Wood, in a plank as large as the one needed for this speaker would be pricey, and I chose to machine the wood, which involves no tooling cost but raises the part cost. The wood has unique mechanical and acoustical properties and its aesthetic appeal and relationship to musical instruments is why it was choosen.

The Man

Mechanical Details

Main body Quantity: 1 material: English Walnut Wood Nominal wall thickness: .4�

Fastening Methods Low Volume Wood to metal- screws Screws- 1� diameter flat countersunk head Wood to extruded speaker rod - screwed in Speaker to speaker rod- slot fit

3.500

3.199 2.700

.400

32.000

Main body Quantity: 1 material: English Walnut Wood Nominal wall thickness: .4�

SolidWorks Student Edition.

4.864 .956

1.631

32.000

speaker cover Quantity:41 material: leather

21.200

2.700

R.300

31.200

SolidWorks Student Edition.

For Academic Use Only.

12.260

1.739

11.950

R.300

Quantity:2 material: PP

32.000

SolidWorks Student Edition.

For Academic Use Only.

R.300

speaker rod

.662 3.750

low volume processes CNC Machining - wood

laser cut - Aluminum 4 gauge

Cnc machining is a shaping process that can achieve

lasercutting involves a high powered laser to cut materials.

extreme precision and high-quality parts. It can be

High precision can be obtained and little to no finishing is

used with metal, plastic, wood, stone, composite and

needed. once lasercut the metal is stamped around a mold to

other materials. The machine starts with a large block

take the shape.

of material and gradually cuts away the material with cutters or drills along an x, y, or z axis until the desired shape is achieved. You simply imput the CAD file into the computer and the machine does all the work

Extruded - PolyPropylene Plastics extrusion is a high volume manufacturing process in which raw plastic material is melted and formed into a continuous profile. The plastic is heated then pushed through a die which forms the plastic.

Sewn - leather Sewing is the craft of fastening or attaching objects using stitches made with a needle and thread. Another way to bond the material is with adhesive bonding.

BOM high volume

Part Name Body -part 1 Outline -outline 1 1.2 -outline 2 -outline 3 Speaker holder Speaker cover Speaker Total Tooling Part Speaker & OEM Total Retail Price Ratio

1 100,000 45 $25 100,070 $300 .003

Quantity

Material

4

Arboform

4 4 2 4 2 1 1

Aluminium sheet 12 “ “ “ PP knit fabric Flat Panel Speaker 10 10,000 45 $25 10,070 $300 .03

2 gauge

100 1,000 45 $25 1,070 $300 .3

Process

Size

Weight

Finish

Tooling cost

Part cost

Injection Molding

31.5” x 10” x 1.5”

2 lbs

polished

50,000

6

Stamped “ “ “ Extrusion cut and sewn

31.5” x .5” x .12” 3” x .5” x .12” 10” x .8” x .12” 8” x 6” x .12” 2.75” R x 22.5” 30.5” x 22” x 3.25” 28.5” x 20” x 1.5”

1 lbs .065 lbs .4 lbs .2 lbs .5 lbs .05 lbs 10 lbs

polished “ “ “

30,000

10 1 5 4 3 2 25 $45

1,000 100 45 $25 170 $300 1.76

10,000 10 45 $25 80 $300 3.75

50,000 2 45 25 72 $300 4.17

black

100,000 1 45 25 71 $300 4.23

500 500 10,000 0

1,000,000 .1 45 25 70.1 $300 4.28

The Man

Retail Price $300 Optimum volume Around 35,000 cost to make $75 Due to the large size of the parts each unit would be sold for $300. This is a good comparison to the low

High tooling cost Low part cost

volume version which is considerably more money but less units may be sold. For this to make a good return at least 35,000 units must be sold to make up for the cost of tooling which is high.

Mechanical Details Injection molded part one Quantity:4 material: Arboform Nominal wall thickness: .3 “ two part mold

3 Degree draft

2 degree draft

The Man

The Man 8.724

1.751

32.000

8.424

1.751

SolidWorks Student Edition.

For Academic Use Only.

32.000

31.700

.400 1.739

SolidWorks Student Edition.

For Academic Use Only.

High Volume Fastening Methods

Metal outline 1 & 2

Arboform to Arboform parts- injection molded snaps Arboform to metal- screws Screws- 1� diameter flat countersunk head Extruded piece to Arboform screws in ( holes molded into Arboform)

Quantity:2 of each material: Aluminium

21.200

speaker cover Quantity:41

2.700

The Man

R.300

material: leather

31.200

SolidWorks Student Edition.

For Academic Use Only.

speaker rod Quantity:2 material: PP 12.260

1.739

11.950

R.300

32.000

SolidWorks Student Edition.

For Academic Use Only.

R.300

.662 3.750

high volume Processes Injection molded- Arboform

Stamped- Aluminium sheet metal

Injection molding (British English: moulding) is a manufacturing

Stamping includes a variety of sheet-metal forming

process for producing parts from both thermoplastic and

manufacturing processes. This could be a single stage operation

thermosetting plastic or other materials including metals, glasses,

where every stroke of the press produces the desired form on

elastomers and confections. Material is fed into a heated barrel,

the sheet metal part, or could occur through a series of stages.

mixed, and forced into a mold cavity where it cools and hardens

The process is usually carried out on sheet metal, but can also

to the configuration of the cavity. Arboform is “liquid wood� which

be used on other materials, such as polystyrene.

has the appearance of wood but can be formed like a polymer.

It is made. Lingin (an often-discarded element of regular wood) is combined with natural resins, flax and fibers that can be injected into molds and form extremely complex, precision-shaped objects normally made of conventional, non-biodegradable petroleum-based plastics.

Extruded - PolyPropylene Plastics extrusion is a high volume manufacturing process in which raw plastic material is melted and formed into a continuous profile. The plastic is heated then pushed through a die which forms the plastic.

Leather - Die cut and sewn Sewing is the craft of fastening or attaching objects using stitches made with a needle and thread. Another way to bond the material is with adhesive bonding.

Branding Low Volume

Embroidered Integrated

Embroidery is the handicraft of decorating fabric or other materials with needle and thread or yarn. Embroidery is most often recommended for caps, hats, coats, blankets, dress shirts, denim, stockings, and golf shirts. You input your design in the machine, much like cad, and it embroiders for you.

Pros not removable low cost easy to change if brand name changes

Burned into wood or “branded�

Integrated

Wood branding is when a piece of metal with the logo on it is heated and then pressed onto the wood, burning the logo into the wood. Other types of branding include, freeze branding, electric branding, propane branding, leather branding, skin branding.

Pros not removable low cost unique easy to change if brand name changes

Branding High Volume Silkscreen Printed

Screen printing is a printing technique that uses a woven mesh to support an ink-blocking stencil. The attached stencil forms open areas of mesh that transfer ink or other printable materials which can be pressed through the mesh as a sharp-edged image onto a substrate. A fill blade or squeegee is moved across the screen stencil, forcing or pumping ink into the mesh openings for transfer by capillary action during the squeegee stroke.

Pros not removable low cost easy to change if brand name changes

Electroplated name plate Applied

Electroplating is a plating process in which metal ions in a solution are moved by an electric field to coat an electrode. The process uses electrical current to reduce cations of a desired material from a solution and coat a conductive object with a thin layer of the material, such as a metal.

Pros low part cost easy to remove if brand name changes

The Man

Injection molded into part Integrated

This branding would be integrated into the injection molded part. This has an interesting aesthetic and does not allow the user to remove the label.

Pros not removable low cost

Low Volume

The Man

High Volume

The Man