Jozy Klupar
Hi, I’m Jozy.
Curiosity
Creativity
How does it work?
Getting my hands dirty.
Costume Design Solving Problems
Industrial Design
Materials
Technology
Social Responsibility
Function
Pouf AN AIRATING FRUIT BOWL This project was created from a stainability standpoint. We wanted to embody the words simple and honest taking into consideration the materials, processes, and the affect they have on the environment and the user. Alex Neilson - Joseph Sanchez
Helpful Tools
We used tools such as the Okala Impact assessment, stakeholder needs, ecodesign strategies and lifecycle anaylsis. These allowed us to fully assess all aspects associated with the materials, processes, distribution, instulation, and disposal and calculate the best most, sustainable options. We then performed an Okala Lifecycle Assesment on a commercial product and designed a product that was at least 10% more sustainable than it’s commercial counterpart.
Then we looked into the stakeholders needs and the principles behind EcoDesign. For a product to be successful it needs to meet the needs of four stakeholder categories, environment, user, society, client. The principles behind EcoDesign are to be environmentally benign and economically viable, while sustainable design also has to be socially equitable.
This gave us a deeper understanding of how much energy goes into all processes in creating a product from taking the material out of the ground and into the hands of the consumer.
Team Blue: San Jose State
fruit poof CAD development
exploded view strips of material Base (internal) Base (outer)
16” 15.841
3.25” 3.250
material Choice * Wood veneer * Silicon * Metal mesh
15.841
6”
3.250
6.313
5” 5.000
15.841
3.250
6.313
5.000
15.841
3.250
Using the tools to guide our design. To make the product more sustainable we took the original design which was ten parts not including fasteners, and made the fruit bowl from one piece of sheet metal. To eliminate the fasteners, it is now welded. This also allowed us to only use one material, instead of the two that the previous design had. We did an Okala lifecycle assessment of an existing fruit bowl and compared it to the Pouf. The Pouf’s impact was significantly lower by 30%.
The unique design allows the fruit to be aerated, promoting airflow which ultimately enables the fruit to last longer. As the user eats more fruit the bowl’s profile slowly changes due to the flexibility of the material.
Colorado Bike Bag REFLECTIVE MESSENGER BAGS This project was created as a solution to allow cyclists to be seen while riding. This was the first project with Sampson Sports softgoods incorporating new technologies with textiles, but there are more to come. This bag is completely waterproof and is in production. I took this product from conception, inital rough sketches, through development, creating patterns and finally to completed outsourced production.
Laced A METAL FABRICATED CHAIR This project was created from a prototyping standpoint. I wanted to explore materials I had never worked with, learn new techniques and experiment with different machines.
I began pulling inspiration from the idea of manipulating materials in a way that pushed their limitations. I was intrigued by materials that simulate characteristics of another material.
I wanted to simulate fabric, so I began sketching flowy fabrics draped over chairs. I then explored options for materials and chose something as far away from fabric as possible.
Making It!
Weld it
Grind it
Brush it
Waterjet cut it
Fabricate A NEW SEWING EXPERIENCE In 1790, the first workable sewing machine was patented by the British inventor Thomas Saint. From that time, the function of the machine has changed very little and the main functioning elements have remained the same. The same can be said about the design of the outer shell of the sewing machine, until now.
What’s the Problem? The real issues are regarding the bobbins. They run out of thread often and are difficult and time consuming to replace. Thread often gets tangled without the users knowledge, which means the piece has to be resewn and it is difficult to fix this thread build-up because it is inside the machine and there is no way to access it. The back stitch button is annoying to use because the user has to stop guiding the fabric and push a button on the machine, and the foot pedal cord constantly gets in the way.
“I want to change the position/orientation of the bobbin.”
“I wish it was easy to replace the parts in my machine.”
shell limits ability to change broken parts
“Threading and replacing the bobbin takes too much time.”
No visibility of thread backup
The backstitch button is on the machine
Who is she? The woman I am designing for is in her late 20’s early 30’s who is a costume designer. She is a workaholic and will not put her name on something that is not worthy of it. She is frequently in the costume shop using the machines, but they are older, aggressive and frustrating to use, the threads constantly snapping, the bobbins are always running out, and they seem to always be breaking. She needs a machine that.... durable easily changable
looks elegant
easy to replace parts
inspires her work
does not waste time
is enjoyable to use
Requirements Her machine must have a back stitch, bobbin threader, speed wheel, foot pedal, stitch length and width adjustment. It must be Sophisticated Elegant Inspirational Timeless Easy to use Efficient Dependable
Belt Mechanism
Compactability
Form/scale study
Verticle surface board Lazy susan surface board
Accessability to parts
Ideation & Exploration
Vertical surface board
With the first concept I rotated the sewing surface. which allows you to have more room to set up the piece you are going to sew. When sewing you focus on the fabric before it gets sewn. You do not focus on the needle, which facilitates more room to line up your stitch. With the second mock up I wanted to give the user more room to move the fabric. I then tried to eliminate the top which constantly gets in the
Lazy susan surface board
way of the fabric. This concept hung on the wall, allowing for more room while also enhancing stability with a rotating surface board. The third concept combined the verticle surface board idea and experimented with a form that mimices shapes found in fabric pieces.
Using Belts instead of drive shafts
tension wheel
Final Design
presser foot lever
This design meets the requirements I sent earlier in the process. This machine has a back stitch (built into the foot pedal), foot pedal, bobbin threader, speed wheel, stitch length and width adjustment.
stitch length adjuster Eliminates the need for a bobin threader by using a whole spool
Vertical surface board that rotates to get that perfect stitch.
hand wheel
Foot pedal that does a forward stitch as well as a backward stitch.
Fabric cord that easily rolls up to help prevent tangling.
foot pedal forward and back stitch
Full spool for the bobbin eliminates the need to thread the bobbin. This way the bobbin lasts longer and no time is wasted threading the bobbin.
Exposed interior allows for easier access to tangled thread.
How does it work? This works almost exactly like a usual sewing machine which uses a drive shaft but instead of powering gears it powers belts. Attached to the main belt is a scottish yoke which is attached to the needle shaft and powers it up and down. At the same time that the belt is moving to power the needle shaft the motor is also moving a drive shaft which moves the bobbin case under the needle.
4
3
The belt is made of Kevlar, which almost never needs to be replaced and has an extremely high strength-to-weight ratio. The benefit of the belt allows for more freedom with the form and significantly decreases the amount of parts needed.
Belts vs. Driveshafts
5 2 1
Material study
vacuum bag molding: Fiberglass
injection molding: Polypropylene
injection molding: Arboform
machined metal
Inspirational Elegant Dependable Efficient Sophisticated It inspires her and fuels her creativity. She can hear the sound of the motor and see the movement of the belts and it no longer feels like she is doing any work, the machine does it all for her. When she is done she leaves it out for everyone to admire.
Simple Limb Initiative AN AFFORDABLE PROSTHETIC LIMB The goal for this project was to provide an affordable and accessible option for children in Cambodia who are missing limbs. Physical, cultural, emotional, and social elements had to be anaylized to allow for the child to be self sufficient and to participate in activities of play, school, and home.
25 Million Amputees in the world
80% Live in
Developing Countries
2% Have access
to the help they need
The information presented here is from the International Committee of the Red Cross [ICRC] document Anti-personnel Mines: An Overview, 1996. The ICRC bases all its figure
es on land mine numbers on the UN Demining Database.
CAMBODIA home to
50,000
landmine survivors
250,000 Amputees are landmine victims
110 Million landmines 64 countries
6 Million Landmines in Cambodia
Decades of conflict has transformed Cambodia into a country that is littered with landmines and unexploded ordinances (UXO).
Business Model
Clinic
Local Transport
Amputee
C
The clinic downloads our files from our website. They then print out the parts, assembly, and pattern manuals. They gather the required materials and travel around to various towns providing materials for new fittings,
Credit : Anne To
maintenance, and education. This would be done twice a year.
Mobile Clinic
Product Parts are outsourced or manufactured in Phnom Penh.
Product Parts comprised of found materials and are self assembled.
A traveling clinic moves from town to town by road using motorcycles or waterways providing materials for new fittings, refitting, maintenance, education, instruction, and convenience.
This prosthesis needs to be Easily Transported Affordable Comfortable Desirable Culturally acceptable Require least amount of materials/processes/tools Require little to no help(clinic) adjusting/fitting Self repairable
Goal To allow limb deficient children to be self sufficient and participate in activities of play, school and home.
Ideation I wanted to focus on natural materials that could be aquired locally by the user. This would reduce the price and make the prosthesis more customizable. One of my main goals for the socket was to make it universal. I wanted it to be self made and adjustable because the user would be be able to have the equipment to make the socket a perfect fit, like they do at the clinics.
I experimented with resin soaked burlap and various other matierials for the socket. I ended up focusing on using a sheet of HDPE. then tried various fastening methods, from leather belts, to boot like lace up nylon. But I needed something that was quick and easy but would hold. So I decided on a lace up where you wrap the string twice around a screw or round piece.
Back Socket
Front Socket
Cup
Pylon
Foot Sleave
Foot Structure
Foot Sole
There are three printed booklets needed. The parts booklet tells the user how to make the custom parts. The assembly booklet instructs the user on how to assemble each part after it is altered. The pattern booklet has small medium and large
PAR TS
ASS EM
BLY
PAT TE
RNs
patterns for the user to trace to make some of the custom parts.
1 2 3
Purchased materials that travel with clinic
4
5
1 Sheet - SOCKET 2 Structure - FOOT 3 Cup - CONNECTION 4 L Bracket - FOOT 5 Aesthetic Screws - SOCKET 7 6 Threaded inset - CONNECTION 7 Screw
6
Locally purchases materials (user purchases)
SolidWorks Student Edition. For Academic Use Only. 1 2 3
1 Fabric lining(inner/outter) - SOCKET 2 Fabric cover - FOOT 3 Thread
.noitidE tnedutS skroWdiloS .ylnO esU cimedacA roF Found materials (user collects) 1 Bamboo - PYLON 2 Rubber reinforcement - FOOT 3 Rubber sole - FOOT 4 Tires - FOOT
1
2
3
4
This is a self adjusting universal socket. It can be adjusted to the users residual limb throughout the day/week/year depending on the users weight loss/gain, growing, hydration/comfort levels.
By using a free, renewable resource for the pylon, it can be easily replaced whenever the user needs.
The fabric is purchased locally and allows for the user to add
By wrapping material around the foot it
their own personality to their
allows for the user to change the shape
prosthesis.
of foot easily, for different activities and terrain.
Our team
Cambodia Simple Limb Initiative
Business Model
Trans-femoral Prosthesis
86% of the country lives in rural area...
Landmines
Discrimination
Decades of conflict has transformed Cambodia into a country that is littered with landmines and unexploded ordinances.
Discrimination and social stigma are recurring themes among disabled Cambodians.
Above Knee Prosthesis
Our group business model consist of delivering prostheses directly to the amputees with help from partner clinics throughout Cambodia. We are a mobile clinic, working with established clinics as well as local transportation to distribute to amputees in both city and rural areas in Cambodia.
This above-Knee Prosthetic, provides stability and support, the customizable ;socket allows for tightening according to the days needs, many parts of this prosthetic are DIY and hand made, which makes it really affordable and easy to replace, and customize according to preferences and size.
Children are often bullied at school and parents of children with disabilities are disapproved of, particularly if they decide not to abandon their newborns.
Mobile Clinic
Missing Limb Epidemic Some who are unable to receive proper treatment make do by fashioning crude homemade prostheses that offer little in the way of functionality and durability. The high number of amputees without prostheses is due in part to the low level of distribution and the lack of knowledge of the help that is available to them.
How can we engage with Cambodian communities to instill child amputees with a renewed sense of optimism and independence?
Product parts are outsourced or manufactured in Phnom Penh, Cambodia.
Product parts are comprised of found materials and are self-assembled.
Strap
Socket
Support Structure
Knee
A mobile clinic moves from town to town by road or waterways providing materials for new fitting, refitting, maintenance, education, instruction, and convenience.
Pylon
Foot
Trans-humeral Prosthesis
Trans-tibial Prosthesis
Trans-humeral Prosthesis
Trans-tibial Prosthesis
Below Knee Prosthesis
Above Elbow Prosthesis Designing for children living in the most rural sectors of Cambodia meant creating limbs that were highly replaceable and customizable. The design of this limb tapped into Cambodia’s booming construction industry and utilized massed produced materials that would be highly available and easy to source. Designing for rural life meant creating parts that users could shape and replace themselves. The ability to add on low cost end terminals opened the opportunity for users to create for conditions specific to the challenges of their lifestyle needs.
Discovering that the primary reason why child amputees in Cambodia did not have a prosthetic was a distribution problem rather than a financial problem was a huge driving factor in my decision making. Instead of making the cheapest prosthesis possible, I decided that it was important to make a prosthetic that could be made to fit any child between the ages 10-14. This prosthetic would have to be easily transported to the rural regions of Cambodia and be easily modified to fit any child. This prosthetic would become a placeholder until the amputee can travel to one of the government funded prosthesis clinics and be given a custom fit prosthetic for free.
Above Elbow Prosthesis
Below Knee Prosthesis
This above-elbow child prosthesis utilizes construction materials such as PVC pipe that can be easily found in Cambodia. The parts are customizable and are assembled together by the local mobile clinics to facilitate the distribution of the prostheses in the rural area where many amputees don’t have access to health care. My AE prosthesis is extremely affordable and does not require any expensive tools to build it.
The majority of the materials and assembly are DIY which allows for the prosthetic to be extrememly affordable, only $9. It also allows for the user to personalize and customize their prosthesis as they grow taller and their preferences change.
This is a self adjusting universal socket. It can
Harness
be adjusted to the users
Socket
residual limb throughout the day/week/year depending on the users
Socket
harness
Foot Component Forearm Fairing
Actuation Cable Elbow
Rubber Band End Terminal
Connector
By using a free, renewable
hydration/comfort levels.
resource for the pylon, it can be easily replaced whenever
Lacing
the user needs. wrist unit forearm
Shock Support
terminal device socket elbow joint
Threaded Wrist Unit
weight loss/gain, growing,
The fabric is purchased locally and allows for
By wrapping material around
the user to add their
the foot it allows for the user to
own personality to their
change the shape of foot easily
prosthesis.
for different activities.
The
Modern Manta Energy Harvesting Textile The Modern Manta allows for people in the developing world the ability to own energy-harvesting textiles, giving them the freedom to have renewable power and light whenever, wherever they need.
Research Twelve million people in rural Peru do not have access to electricity. This lack of light causes a decrease in the wellbeing of the individual and their family, lack of productivity, and lack of community. I first observed this need while doing an internship in rural Peru. I had personal experience viewing this problem and the impact it has on individuals and their communities.
Initial Ideation
Peruvian
texiles
I gravitated toward using textiles for a few reasons. The main deciding factor, was because of affordability. With textiles, there is no tooling cost and they can be made locally. Textiles are an integral part of Peruvian culture. The patterns are full of color and texture. Every Peruvian woman can be found wearing a manta at some point during her day.
Modern Technology + Traditional Textiles I wanted to incorporate modern technology with traditional textiles to allow the technology to be more adaptable by those living in Peru. The Manta, is a Peruvian garment that can be worn as a shawl, wrapping over the shoulders of women. It is worn by almost all women, everyday. Aspects from the Manta can be seen in the final design as well as similar elements from their traditional dress.
Final Concept Affordability and user interaction were the main focus of this project. Because of that, I gravitated toward using textiles because they can be made locally, require no tooling cost, and they are such an interregnal part of Peruvian culture. Integrating the technology into the textile took a few rounds of prototyping as well as designing the pattern and wiring the electronics.
Energy Harvesting Textile 4 solar cells 8 LED’s 1 battery
Affordable: $16.80 Practical: Charges on or off the body Versatile: Many ways to wear it Durable: Easy to clean Renewable Energy
This energy harvesting textile needs 6 hours to fully charge the battery. The battery then powers 4 LED’s for 8 hours or all 8 LED’s for 4 hours before it needs to be charged again. It is only $16.80 or 40 Peruvian Nuevo Sole which is somewhat affordable but gives reliable renewable light unlike the alternative, kerosene lanterns, candles or battery operated flashlights which are are insufficient, hazardous, and unhealthy. The battery can withstand 10,000 charge/discharge cycles which under normal conditions is 30 years.
How does it work?
1
3
2
4
5
6
How can it be used?
Ingrain FLAT PANEL SPEAKER This project was designed from a manufactuing standpoint. I wanted to design a speaker from a low production perspective then translate the same design for high production. This gave me a full understanding of different manufacturing processes, materials, and their relation to varying volumes in production.
Who is he? My persona is an art gallery owner who is well established in the art world and comes from a wealthy family. He is a collector of fine art, books, and exotic films. He has an eclectic collection of unique expensive items. He is a single socialite in his mid thirties who is constantly entertaining guests. 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.
creative sophisticated intelligent tech-savey
large space to entertain guests
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.
inspiration
Final Direction
Retail Price $3000 Optimum volume Around 75 cost to make $750 High part cost Low - no tooling cost
Low Volume Production BOM Part Name
#
Material
Process
Size
Weight
Finish
Tooling cost
Part cost
-part 1
1
Dark Walnut
CNC Machined
31.5” x 10” x 1.5”
8 lbs
polished
0
175
-part 2
1
Dark Walnut
CNC Machined
31.5” x 13” x 1.5”
8 lbs
polished
0
175
2
Aluminium sheet 4
Lasercut
31.5” x .5” x .12”
1 lbs
“
0
25
3” x .5” x .12”
.065 lbs
“
3 10
Body
Outline -outline 1 1.2 -outline 2
2
“
“
10” x .8” x .12”
.4 lbs
“
-outline 3
4
“
“
8” x 6” x .12”
.2 lbs
“
Speaker holder
2
PP
Extrusion
2.75” R x 22.5”
.5 lbs
Speaker cover
1
knit fabric
cut and sewn
30.5” x 22” x 3.25”
.025 lbs
Speaker
1
Flat Panel Speaker
28.5” x 20” x 1.5”
10 lbs
Total
black
7 10,000
3
0
2 200 $400
Retail Price $300 Optimum volume Around 35,000 cost to make $75 High tooling cost Low part cost
High Volume Production BOM Part Name
Quantity
Material
Process
Size
Weight
Finish
Tooling cost
Part cost
4
Arboform
Injection Molding
31.5” x 10” x 1.5”
2 lbs
polished
50,000
6
4
Aluminium sheet 12 gauge
Stamped
31.5” x .5” x .12”
1 lbs
polished
30,000
10
Body -part 1 Outline -outline 1
4
“
“
3” x .5” x .12”
.065 lbs
“
-outline 2
1.2
2
“
“
10” x .8” x .12”
.4 lbs
“
500
5
-outline 3
4
“
“
8” x 6” x .12”
.2 lbs
“
500
4
Speaker holder
2
PP
Extrusion
2.75” R x 22.5”
.5 lbs
10,000
3
Speaker cover
1
knit fabric
cut and sewn
30.5” x 22” x 3.25”
.05 lbs
0
2
Speaker
1
Flat Panel Speaker
28.5” x 20” x 1.5”
10 lbs
Total
black
1
25 $45
Manufacturing Low Volume CNC Machining wood Laser Cut Aluminum Sheet 4 gauge Extruded PolyPropylene Sewn 1
10
50
100
1,000
5,000
10,000
Tooling
10,000
1,000
200
100
10
4
2
Part
400
400
400
400
400
400
400
Speaker & OEM
200
200
200
200
200
200
200
Total
10,600
1,600
800
700
610
604
602
Retail Price
$3000
$3000
$3000
$3000
$3000
$3000
$3000
Ratio
.3
1.9
3.75
4.3
4.9
5
5
Leather
Manufacturing High Volume Injection Molding Arboform Stamped Aluminum Sheet Extruded PolyPropylene Die Cut & Sewn Leather
1
10
100
1,000
10,000
50,000
100,000
1,000,000
Tooling
100,000
10,000
1,000
100
10
2
1
.1
Part
45
45
45
45
45
45
45
45
Speaker & OEM
$25
$25
$25
$25
$25
25
25
25
Total
100,070
10,070
1,070
170
80
72
71
70.1
Retail Price
$300
$300
$300
$300
$300
$300
$300
$300
Ratio
.003
.03
.3
1.76
3.75
4.17
4.23
4.28
Zoom SOLIDWORKS ROCKET CAR This is a CO2 powered Rocket Car. The front curve has aerodynamic qualities that allow it to pass through the air at an extremely quick speed. Because it is low to the ground and the nose points slightly downward air does not slow it down.
It is made up of two injection molded polypropylene shell pieces, four lazer cut wheels and two axels. It has sufficient draft so it is possible to go to production. The C02 is held in with 3 upper ribs and 3 lower ribs. The top and bottom are held together with snaps.
Rear snaps
Front snaps
Renegade Poultry BRANDING A POULTRY FARM I worked with an Albuquerque based poultry farm, dedicated to local - sustainable - economic growth in the community. They sell their products at the local Coop and farmer’s markets. I gave them a logo for their shrinkwrapped poultry, egg cartons, and various other paper goods. They also have a few branches of this company; rent-a-coop and butcher block.
This is Renegade Poultry’s Rent-A-Coop. I wanted to keep a similar logo, to not confuse the consumer of the connection. I did not design the coop itself, but I designed the logo as well as the brand for the side of the coop.
nt but all mitme the com fu o n! n
egade n e r
re nt-a-coop new mexico raised
Thank you jozyklupar@gmail.com 505.269.7076