Product Design Engineering Brochure 2021

PRODUCT DESIGN ENGINEERING PROJECTS 2021

ENGINEERING DESIGNERS 2021

Contents Welcome 02 About the Wolfson School

03

Introduction to Product Design Engineering Projects

05

Student Projects

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Welcome At the Wolfson School of Mechanical, Electrical and Manufacturing Engineering, we are committed to equipping the next generation of engineering and product designers with the skills they need to succeed.

This book showcases the accumulation of these: innovation, creativity, analytical and communication skills in the presentation of the individual project work from our thirdyear Product Design Engineering students and group projects from the fourth year Project Engineering students within the School.

The quality of their work reflects the expertise they have gained during their time with us, and in many cases also the experiences gained during the placement year.

The school is proud to produce students with a passion for engineering, who will thrive in any business and industry environments.

I hope you will find the book interesting, inspiring and informative.

Paul Conway Dean of Wolfson School

PDE PROJECTS 2021

About the Wolfson School of Mechanical, Electrical and Manufacturing Engineering As one of the biggest engineering schools of its kind in the UK, the Wolfson School of Mechanical, Electrical and Manufacturing Engineering has an international reputation for being at the forefront of technological innovation and for maintaining extensive links with industry.

As one of the biggest engineering schools of its kind in the UK, the Wolfson School of Mechanical, Electrical and Manufacturing Engineering has an international reputation for being at the forefront of technological innovation and for maintaining extensive links with industry.

Our graduates are testament to our success, helping to provide industry with the skills and knowledge to give them the competitive edge required to succeed in the 21st century.

In addition to holding a prestigious Queen’s Anniversary Prize in the category of Optical Engineering and High Value Manufacturing : applications and knowledge transfer, we are home to two EPSRC Doctoral Training Centres, for Innovative Manufacturing in Regenerative Medicine and for Embedded Intelligence.

Our industrially focused research enables us to work with some of the world’s most renowned engineering companies and helps us to generate around £12million in external research contracts each year.

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PDE PROJECTS 2021

Introduction to Product Design Engineering Projects Each PDE project presented in this brochure was undertaken by an individual Part C student over two semesters and under the primary supervision of a dedicated member of the academic staff. In many cases these projects had industrial sponsors who provided additional financial, technical and supervisory support. This year we have over 100 projects in total, covering a broad spectrum of engineering challenges. The PDE project briefs arise from a variety of sources, including: academic research, industrial partners, and from the students themselves.

However, they all provide an engineering challenge that allows the students to apply the skills and knowledge acquired during their degree program. These projects are both critical to, and an integral part of, the intended learning outcomes of the degree program as accredited by the IMechE, IET and IED.

We are extremely grateful to our industrial partners for the financial, technical and practical support they have provided, as well as to our own in-house technical teams and support staff who have enabled and contributed to the successful completion of some highly challenging projects that have given the students a unique and rewarding learning experience. Finally, I would like to wish all the graduating students the reatest success in their future careers.

For those continuing with their academic studies, congratulations and see you in the new semester.

Dr James Colwill PDE Programme Director

Despite the challenges this year due to Covid restrictions, lockdowns and closures, it is commendable of both students and supporting staff that so many projects managed to include practical work, prototyping manufacture and testing.

I am proud of what our students have achieved this year and it is a clear demonstration of their resilience and ingenuity that will serve them well after graduation.

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PRODUCT DESIGN ENGINEERING PROJECTS

Nomad ergonomic research study Digital nomads are technology-enabled workers with location independence that choose to travel for leisure. The population is predicted to increase CHARLOTTE rapidly. The current musculoskeletal disorder risk of nomads is discovered to LOUISE ALLEN be higher than office workers due to their E: charlottelouallen@gmail. work equipment. com The incidence of neck pain and shoulder /charlotte-louise-allen

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SUPERVISORS: Dr Rebecca Grant Dr Mey Goh

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pain is found to grow with increased screen time in this study. Notably, neck (20%) and shoulder pain (27%) were found to be most prevalent in the market survey.

Therefore, the redesign of workspaces for digital nomads is proposed to reduce health risks for the digital nomadic population.

The redesigned interior reduces the risk of work-related pain due to equipment by 80% from the most popular van interiors. It successfully reduces the risk of pain to the same level as an office workstation according to ROSA ergonomic assessment method.

— “After designing pet furniture at Omlet on my placement year, I am going to apply my passion for furniture design to convert vans. ” —

PDE PROJECTS 2021

Additive manufacture of 3D electronic devices Additive manufacturing has the potential to produce 3D electronic devices, which conventional methods struggle to do. A project was conducted to further research into this area. Using a fused deposition modelling (FDM) additive machine, three methods for creating electronic devices were tested and evaluated. These were: using conductive filaments on a dual extruder machine; injecting conductive paint into printed channels; and placing small wires into printed channels.

Successful devices were created using each process, albeit to varying degrees.

Due to this project’s limited time, they could not be fully explored but did all prove that they have potential. The conductive filament approach was also used to create a switch, showing off additives unique ability to produce components directly into devices. Future research is required however to take these processes to a commercial level.

— “Planning on finishing my masters in PDE end of June 2022 and then hoping to work in an innovative company, working on developing new technology and products.”

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TOBY ALLEN E: Toby@fetcham.com /toby-allen-95bab4158

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SUPERVISOR: Dr David Hutt

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PRODUCT DESIGN ENGINEERING PROJECTS

Graphic simulation of railway wheelsets

TAMILORE AYO-FAMOLA E: tamiayofamola@yahoo. co.uk /tamilore-ayo-famola3a2554181

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SUPERVISOR: Halim Sha

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The railway network in the United Kingdom is one of the busiest on the continent with 2566 stations and 15, 847 km of track. Since its development in the 19th century, turnouts have been a vital but weak component of the railway.

They allow trains to make numerous connections every day but at the cost of a complex structure, short lifespan, safety issues, and high maintenance effort.

This project uses a range of 3D visualisation techniques; modelling, rendering, animation, rigging, and simulation, to present the elements of a functional turnout design.

In particular, the aim is to generate a graphic simulation of the wheel and rail interaction, as described by Klingel’s and Redtenbacher’s formulas, in the straight and curved turnout routes. The turnout is right-handed design, based on a standard gauge, European 60E1 series track and the wheelset consist of 2 solid wheels mounted in a rigid axle.

In industry, railway projects can significantly improve their budget and time efficiency by making use of a highperformance graphic simulation software.

Any changes to the planning or design inputs of a turnout are immediately reflected in the digital environment, optimising the design engineer’s ease of understanding with much shorter feedback loops and greatly streamlined workflow. Additionally, the quality of the final delivery is improved by the software’s capability for producing complex splines and surface geometry.

— “This summer I will be working as an intern for an Attraction Safety team. After completing my master’s degree at Loughborough, I will continue pursuing a career in themed entertainment.”

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PDE PROJECTS 2021

Feasibility of FDM 3D printing for a modern music box Modern advancements in music technologies have surpassed the capabilities of the traditional music box, making this once pioneering product obsolete. However, the history and authenticity of the music box cannot be lost, therefore this product was revolutionised. This investigation integrated modern Fused Deposition Modelling (FDM) 3D printing technologies to create a custom product, capable of instantaneously converting modern songs to ‘print and play’ formats. A review of current literature identified a gap in the market for a fully 3D printed music box that can produce an authentic sound and play a range of popular songs with relative ease.

Separating the product into individual feasibility sections provided a focused design method and allowed for comprehensive conclusions to be drawn.

The mainspring winding mechanism is a particular area to note, where several experiments are carried out to design

a working mechanism. However, it was concluded that further work is necessary to produce a fully functioning design. The final product combines an authentic sound through the use of a carbon steel comb, with a modern 3D printing aesthetic to appeal to a wide range of consumers. This is combined with a sophisticated and comprehensive software program that can transform the users’ midi files into 3D printable parts in a minimum of seven clicks.

— “After a Product Design Engineering Masters, my aim is to become a Chartered Engineer and begin a career in the design engineering sector with specific focus on 3D printing technologies.”

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FAHEEM AZIZ E: aziz.faheem2@gmail.com /faheem-aziz-78074b158

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SUPERVISOR: Dr. Rebecca Grant

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PRODUCT DESIGN ENGINEERING PROJECTS

Design of an assisted motorised scraper

RYAN BOOTH E: RyanBooth47.rb@gmail. com /ryan-booth-designengineer

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SUPERVISOR: Lewis Jones

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As farm animals are often kept indoors during the winter months, they must have their uneaten, unreachable food pushed up to their feed barrier, and their waste cleared to improve wellbeing and reduce health issues. The process of doing this without investing in machinery costing tens of thousands of pounds, requires manual tools which are physically exertive, time-consuming, and often contributors to long term musculoskeletal issues.

The aim of this project was to create a device that was significantly cheaper than the high-powered machinery available on the market and replicate their high productivity. Meanwhile possessing the maneuverability of a manual tool without causing strain to the user.

The designed product uses two attachments, one of which is a dual directional, V-shaped item to push the food up to the animals’ feed barrier.

While the second attachment uses wings and a rubber blade to capture a wave of slurry and push it to a drainage point.

This is achieved using an electrically powered, motor driven device with the farmer walking behind to steer along the desired path. Engineering drawings of the produced design were drafted ready for a full-scale prototype to be built and sold by an industry sponsor.

— “After completing my Masters in Product Design Engineering, my aim is to begin a career in the agricultural or environmental engineering sector. ” —

PDE PROJECTS 2021

Ergonomic design of alternative communication device for breathing pattern interpretation The project aim was to develop a design of ergonomic housing for an augmented and alternative communication (AAC) device.

The AAC technology uses a breath flow system to interpret the breath pressure of the user which when sent to a phone via Bluetooth produces the corresponding message. Technology and housing play an important part in the mental and physical health of people with communication difficulties. Creating an ergonomic housing, allowing for the user to feel comfortable during use, makes for the most effective use of the AAC technology and a more satisfied user. In addition, ensuring the technology is accurately protected and assisted will boost function and is integral for design optimization.

A literature search detailing anthropometrics, the literature surrounding the subject of AAC technology, and market analysis were utilised in developing initial designs. These were then analysed through the use of a survey,

testing, and a Pugh matrix.

A test platform was created to test a variety of aspects, measuring the success of the design and validating its KEELAN BURGESS functionality. In which results were used to enhance the design of the proof of E: keelanburgess@gmail.com concept (POC). /keelan-burgess A fully functional POC was created.

The final design is an earpiece that holds ­— the electronic components, connected to SUPERVISOR: an armband to hold the battery for the Dr Sijung Hu devices charge. This was able to take a ­— variety of breath readings.

— “Before completing my integrated masters in PDE (Meng) I am aiming to gain work experience through summer placements. After completion, I would like to work within design consultancy.”

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PRODUCT DESIGN ENGINEERING PROJECTS

Wear analysis of high-performance ball type continuous velocity joints including microslip LIBBY BUTTARS E: buttarslibby@gmail.com /libby-buttars-72498b17b

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SUPERVISOR: Nick Morris

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High performance constant velocity joints need to experience as little wear as possible in operation to prevent a decrease in the performance capabilities.

This work concentrates on creating a mathematical model in MATLAB to predict the wear rates of CV joints.

Wear due to microslip and slip has been considered while also taking into account the wear over time.

Sliding distance has been calculated, along with wear over time, to find the total wear of the tracks of the CV joint.

This data has then been used to see how the design of the joint can be improved to decrease the wear rate while still maintaining the performance capabilities.

— “I am aiming to complete a Masters degree in Product Design Engineering leading to a design engineering career in the automotive industry.”

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PDE PROJECTS 2021

Design for manufacture of a “better” mountain bike dropper post remote Modern mountain bikes are more capable and popular than ever, this is partly due to the dropper post, a system that allows the saddle height to be adjusted on the fly via the operation of a remote. Despite dropper posts improving exponentially since their introduction, the remotes used to actuate them have been left behind, often cheap, wobbly, have poor ergonomics and often lead to a compromise in position. Crashing is inevitable when mountain biking dropper remotes are in a highly exposed areas, often resulting in them breaking.

Involving market research, concept development, detailed design and design for manufacture.

Resulting in a remote with 4 axes of adjustment, offering 25mm reach adjustment, 90⁰ roll adjustment, 45⁰ Yaw adjustment and 10mm Pitch adjustment.

Offering an adjustability envelope oven

300% bigger than any of the current market offerings. As well as a wedge lock breakaway feature allowing the remote to “flip” out of the way in the KIT BUTTERWORTH event of a crash, reducing the likelihood of the remote being damaged. The design is validated with FEA simulation E: kitobutterworth@gmail.com for the loads applied in its intended /kit-butterworth-68974a158 use, spring stiffness calculations to validate the wedge lock system as well ­— as a manufacturing a fully functioning SUPERVISOR: prototype, manually machined form Lewis Jones aluminium that has been tested for over 230km with various dropper posts, ­— with no major issues. Full engineering drawings, BOM and costing was completed showing this product can be manufactured at a competitive price.

— “Design and manufacture bespoke bicycle frames.”

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PRODUCT DESIGN ENGINEERING PROJECTS

Development of a biocompatible aortic valve scaffold using 3D printing

KELLY CHAN E: kellywkchan@gmail.com /kelly-chan-

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SUPERVISOR: Sotiris Korossis

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Cardiovascular diseases are the leading cause of deaths worldwide and account for 27% of all deaths in the UK. The aortic valve is one of the four heart valves and controls the flow of oxygen-rich blood from the heart to the rest of the body.

Patients with severe cases of Aortic Valve Disease may require valve replacement, with a mechanical, bioprosthetic or human donor valve.

Tissue engineering uses cells, scaffolds and signals to create functional constructs that can replace, repair or regenerate damaged tissues. Scaffolds provide the support structure upon which cells can grow and form tissue. Tissue engineered valves have potential to have improved functionality, compared to existing replacements, and be customisable to the patient.

This project aims to develop a biocompatible aortic valve scaffold using 3D printing.

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A 3D CAD model of an idealised aortic valve and its matching negative model were created so the valve could be manufactured using 3D printing and casting methods. 3D printing is a promising method to manufacture tissue engineered scaffolds because of the precise design control over the printed structure, on a micro-to macro-scale. Casting allows for a range of biocompatible materials to be utilised and the valves can be post-processed effectively for cell seeding of the scaffold.

— “Following the completion of my Masters in Product Design Engineering, I hope to work in the Healthcare or Consumer Products industries.”

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PDE PROJECTS 2021

Design and development of a length counter device for recreational swimmers The aim of this project was to develop a swimming length counting system that provided relative accuracy of results whilst staying affordable and accessible for recreational swimmers. Key design criteria were formed through feedback from a market survey which was referred to throughout the design process. An iterative ideation phase demonstrated conceptualisation of several solutions to the stated project brief.

Proof of concept was shown for a length counting method through the development and testing of an Arduino prototype. Data fusion techniques were utilised to combine the gyroscope and accelerometer data output of a 6 axis inertial measurement unit. The complementary filter used, produced a smoothed data output which was then analysed to distinguish 180 degree turns of the swimmer, hence determining if a length had been completed.

Insight from market research suggesting that current swimming trackers were too expensive for most recreational swimmers to consider purchasing, led to the proposal for a product service system. This enabled the final concept to achieve the overarching objective of the project; to design a tracker that was more accessible for recreational swimmers.

Costing and profitability were analysed to prove the viability of this strategy.

— “Following graduation, I look forward to travelling and working overseas. Ultimately, my aim is to join or start my own company that is driven by innovation and sustainability.”

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NICK CHARALAMBOU E: nickchara@live.co.uk /nickcharalambou-b75749158

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SUPERVISOR: Laura Justham

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PRODUCT DESIGN ENGINEERING PROJECTS

End of life proposal for grp boats

SAM CLAYTON

There is ever increasing pressure on all industries to become more sustainable and boats manufactured from GRP have their own unique set of challenges regarding end of life disposal. Current options are costly resulting in an increasing issue of accumulated old watercraft.

E: Sam.t.clayton@gmail.com This project aims to generate a proposal to sustainably recover GRP from /samuel-claytonwatercraft and to identify a profitable 77657b15b method of recycling the waste GRP hulls.

There are 3 main areas that need to be ­— addressed; reduction of transportation SUPERVISOR: cost, reduction of dismantling cost, Paul King and increase in the value of recovered ­— material. These areas are divided into a two-part solution. Part 1, material recovery, aims to reduce the cost of transporting and dismantling the boats. Part 2, material recycling, aims to maximise the value of the material extracted from the empty GRP hulls. A broad spectrum of potential solutions were explored analysed and compared using tools such a life cycle assessments.

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In the final proposal, a mobile boat crushing truck is used to reduce the transportation and dismantling costs, and the crushed GRP is mixed with LDPE to produce desirable, timber composite alternatives that can be sold for a profit, thus increasing the value of the recovered material.

The conclusion shows potential for developing a working solution however, additional testing as well as a more detailed real world cost analysis to further validate the findings of this project.

— “After I graduate I will be looking to pursue a career in design and development.

Ideally working on projects from concept to market as I did during my placement year. ” —

PDE PROJECTS 2021

3D modelling of trabecular bone structure for biodegradable implant research Biodegradable metals, such as magnesium alloys, are the next generation of materials used for medical implants such as bone scaffolds and fixation plates. In vivo, the corrosion of a biodegradable implant results in the formation of a new interface with the surrounding bone, for example within the bone marrow cavity. The rate of the corrosion and the interface formed is dependent on the porosity of the bone surrounding it.

This research began by exploring the following methods and techniques to model the bone structure: Repetitive structure modelling, CT scan segmentation; marching cubes method; Gaussian distribution and Voronoi tessellation. The next challenge was identifying the most suitable method for creating representative bone models that could be used in test environments both in computer simulations and real life. The chosen concept was developed

to allow users to easily create a range of models of varying porosity. This concept was then validated through a series of tests designed to prove how successful it TOM COLBOURNE is at generating models which accurately represent the trabecular structure of bone. The results demonstrated that it is E: Tom.colbourne19@gmail. com possible to accurately model the complex trabecular structure of bones and create /tommodels of varying porosity to mimic bones colbourne-670749158 of varying characteristics. It was also possible to create 3-D models which can ­— be 3-D printed and used to further future SUPERVISOR: research in this field.

— “Hoping to go into Medical Design Engineering following my placement year experience at Depuy Synthes (Johnson & Johnson)” —

Yang Liu

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PRODUCT DESIGN ENGINEERING PROJECTS

Exploring the use of additive manufacturing for an artistic kokedama hanging device A recent love and border-line obsession with plants has everyone around the world purchasing more houseplants than ever. It comes as no surprise that new ADRIANA VARGAS ways of growing and displaying plants have risen over the last couple years CORDOVA in the UK, especially when 72% of the E: adrivargas@hotmail.co.uk population owns at least one household plant. Kokedamas, originating from /avargascordova Japan, are ornamental plants that grow in moss balls instead of regular plastic pots.

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SUPERVISORS: Andy Gleadall Daniel Engstrom

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This project is in collaboration with Tranquil Plants (a Loughborough based kokedama manufacturer) and aimed at creating a product that will assist the hanging of kokedamas using additive manufacturing. The vision for the device is an eye-catching, artistic exhibit for a domestic environment with an adjustable height feature.

Since these plants require high humidity levels and have substantial fluctuations in weight over their watering cycle, many design difficulties were faced throughout the project.

The final design composed of a set of three external hanging devices of that were 3D printed from wood filament. This adaptable and aesthetic product will allow customers to display their plants as pieces of artwork. The successful development of the design has led to the fruition of a product that can hopefully be part of the Tranquil Plants product range soon.

— “Upon completion of my masters year, I will be looking forward to a varied and exciting career in the design industry.”

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PDE PROJECTS 2021

Innovative device to combat age related loss of muscle using inertial based resistance training The project aimed to combat problems associated with the decline in muscle as an individual ages, specifically the long term prevention of sarcopenia. It has been well documented that resistance training is the most effective countermeasure for loss of muscle as you age and that it also provides physiological and cognitive benefits. The research showed that it is currently being underutilised as a method to promote longevity and maintained independence throughout life.

This project developed an innovative, intuitive and trackable resistance device used inside the individuals home to promote resistance in the target market.

A mechanism was designed and developed to promote lighter weight resistance training in the form of a continuously variable transmission. This form of training was inspired by the training methods upon the International Space Station where NASA astronauts utilise flywheels to stop zero gravity related

muscle loss. The mechanism developed allowed the force experienced by the user to be changed instantaneously in response to muscle fatigue and to reduce the chance of contractile induced muscle injury, a key concern for the target market.

The mechanism was manufactured using fused deposition modelling and was tested and validated, the larger components were conceptually rendered, and a plan was carried out for the successful implementation of the idea into a business model post university.

— “I would like to be working on designing products that make real world benefits to people. The possibility of further development on this device would also be an exciting prospect.”

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ARLEN CRAWLEY-SMART E: arlensmart@gmail.com /arlen-smart

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SUPERVISOR: Paul Maynard

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PRODUCT DESIGN ENGINEERING PROJECTS

Ergonomic design of a functional face mask against the COVID-19 pandemic

EVE DEAKIN evedeakin.pb.design/blog E: deakineve@gmail.com /evedeakin

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SUPERVISORS: Sijung Hu, Hailing Fu

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Covid-19 has put a strain on the public health sector, the respiratory virus has been shown to be extremely easy to transmit and catch. Although different age groups are generally affected to different degrees of severity, the impact that Covid-19 has had on everyone’s lives has been great. At the same time, there is currently a technological revolution occurring in the form of wearable devices. Initially, large sports companies promoted wearables as a way to help people achieve a better performance and understanding of their body. However, the demographic trend has expanded in recent years, particularly in the midst of the current pandemic. The increase in diagnostic capabilities of smart wearables is allowing patients to play a greater role in preserving good health. The increasing normality of mask wearing for extended lengths of time has also provoked a global movement; to develop the safety, comfort and environmental impact of facemasks.

There is an opportunity to implement existing smart technologies into a facemask which can be used to measure various vital signs as its being worn. This mask will help to support the strained healthcare system as it encourages self-monitoring. The intelligent feedback that smart monitoring devices give will improve communication between patients and doctors, thus improving the efficiency of the healthcare sector as a whole.

— “I am aiming to complete a master’s degree in Product Design Engineering, then begin a career and gain a Chartership in Design Engineering, hopefully working within the healthcare sector.”

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PDE PROJECTS 2021

Evaluation of cost models for laser processing Globalisation has increased competitiveness between manufacturing companies. Laser processing has been proven within industry to be more reliable and to produce better quality items than alternative processes. Additionally, lasers can be adjusted to complete different processes and lends itself to automation, providing more flexibility to manufacturers. Unfortunately, the technology is complex, with many different variations of laser to choose from. Understandably, the challenges and risks associated with the decision can cause businesses to not invest.

Cost modelling is a proven method of helping organisations estimate operating costs and is an important part of building a business case for investment. This project investigated the literature on cost models and data released for a range of laser processes.

A new theoretical cost model was developed using the data collected, with the aim of providing a cost estimation tool that could be used by customers with no knowledge of laser processing. The tool could be used to estimate resource consumption and demonstrate the cost associated with different business priorities such as speed and quality. This tool may help businesses to choose the most appropriate laser for their needs, demonstrate to key stakeholders that the choice was made on a robust basis and thus, hopefully, assist them in implementing laser technology appropriately to improve the competitiveness of their business.

ELIZABETH DREKSLER E: elizabeth.dreksler@gmail.com /elizabeth-dreksler

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SUPERVISOR: Manuela Pacella

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— “I am currently applying for graduate schemes with a focus on business management, with the aim of developing my career goals.”

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PRODUCT DESIGN ENGINEERING PROJECTS

Reactive waves: an engineered sculpture

BORIS ECKERSLEY E: borispe@hotmail.co.uk /boris-eckersley64682717b /eckersleydesign

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SUPERVISOR: Ian Graham

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This project’s goal was to combine engineering, design and artistic principles to produce a physical 3D sculpture that appeals to professionals in all three of these disciplines.

Inspiration gathering from artistic workflows, concept sketching from product design and problem solving and design validation from engineering were used to create a final design.

The resulting sculpture is called reactive waves. It contains a crankshaft to convert rotary motion to linear motion which move hinges back and forth. These hinges bend a series of plastic strips equally out of phase, creating the effect of a wave. The sculpture is motorized and is activated through a PIR which senses movement in the room. The wave can be viewed from a number of angles to provide different visual effects. The QR code on this page can be scanned to see a video of the sculpture in action.

The design was manufactured using a number of easily accessible techniques given the Covid-19 pandemic.

The sculpture was then viewed by volunteers and the feedback recorded for overall evaluation of the sculpture.

— “In the future I plan to gain some paid experience in a design engineering role before perusing a job, or a master’s in design.”

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PDE PROJECTS 2021

Stratasys dimension elite retrofitting with opensource hardware A guide to modifying the Stratasys Dimension Elite is undertaken to see the capabilities of the latest opensource 3D printer technologies. The project records all the information required to rebuild the Stratasys using readily accessible components and the latest opensource 3D printing technologies. The difficulty in the modifications is trying to get the components of the original system, such as the motors or heaters, and having them integrate with the new parts.

The project started with an analysis of the original system. Research was undertaken to identify all the new components required to make the printer operational and seeing which of the original components can be reused.

With all components identified, concept designs and CAD models are produced to implement the components into the machine.

The main outcomes of the project include the specifications of all the components and the conversion guide produced. The raw material cost of the project is estimated to be approximately £2050. If the conversion were provided as a service, labour and design costs could easily raise the value to be over £3000.

The conclusion of the report is that this conversion while possible, is likely to be costly and give minimal returns. The heated chamber technology of the Stratasys printer does not provide significant advantages over some of the mid to high end desktop 3D printers

BEN ELLIOTT E: Elliott.ben64@gmail.com /ben-elliott-designengineer

— SUPERVISOR: Andy Gleadhall

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PRODUCT DESIGN ENGINEERING PROJECTS

Instrument design related to photovoltaics: rapid spectral scanning of flash lamp sources OSCAR FAGG-WOEHLK E: faggwoehlk@live.com /oscar-fagg-woehlk

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SUPERVISOR: Tom Betts

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Solar photovoltaics is the subject studying the conversion of light into electricity and is used profusely in weather analytics, solar power research, and the expanding of knowledge on the most powerful celestial being in our solar system.

These aspects have been combined to investigate the instrument design of technology capable of analysing light at rapid flash speeds, with the project aim being set out as the design and development of the instrument design of a rapid spectral scanner. This project delineates the research, planning, design, and testing of a technology capable of analysing the light of flash lamp sources; a period of light of approximately 0.01 seconds. Current technologies are capable of analysing light waveforms, but none have been produced to do so at such a high speed. This project has used a design development strategy of

initial design concepts, developed through to final design ideas, as well as the software coding and electronic hardware found within photovoltaics. Additive manufacture allowed for the rapid prototyping of instrument housing and design testing, with optical equipment being tested alongside the prototype housing. The outcome includes the final instrument prototype, as well as the test results produced by the technology.

— “In the future, I plan to carry out summer placements to further my engineering experience, as well as continuing my education into my master’s year.”

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PDE PROJECTS 2021

Additive manufacturing of mathematical art This project involved the creation of 3D printed mathematical art. The art was created as a result of plotting the exact path of an Ultimaker 2+ printer head through the utilisation of a software called Full Control.

Through iterative design and altering of print parameters, the concept of traditional 3D printing methods has been broken down and changed to produce plastic 3D printing that has never been seen before. Research into typical FDM manufacture occurred as well as an exploration of new printing techniques such as non-planar printing.

— “I am heading to the UAE to work in Dubai with the largest 3D Printing company in the country.”

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ASA FREEMAN behance.net/gallery/90586941/ Asas-Portfolio E: asagfreeman@gmail.com /asa-freeman-28982617b

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SUPERVISOR: Andy Gleadall

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After several iterative stages of skill and design development, structures were printed that have never been printed before.

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PRODUCT DESIGN ENGINEERING PROJECTS

The effect of Covid-19 on operations management

WILL GERRARD E: Willgerrard0@gmail.com

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SUPERVISOR: Ran Bhamra

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This project investigates the effect Covid-19 had on the technology and automotive industries. Covid-19 was the first worldwide pandemic which saw mass lockdowns causing some industries to plummet in value.

Each industry was investigated using both primary and secondary research, focusing on some major multinational businesses as well as smaller UK based businesses. The Technology industry experienced significantly less issues related to operations during Covid-19 and showed themselves to be more resilient.

In the automotive industry how successful each company was through the pandemic was helped by their operations pre pandemic.

The results showed the automotive industries its operations management policies lacked resilience and suggested a need for change.

— “I am aiming to complete a Masters in Product Design Engineering then begin a career in the design or manufacturing industry. ” —

PDE PROJECTS 2021

Smart campus solution: job application support tool Students have become frustrated with the amount of competition for job roles and the lack of human interaction from recruiters due to the adoption of technology and automation of tasks.

STEM students specifically have a plethora of projects and skills that they want to showcase but feel that they are not given ample opportunity to showcase these skillsets before getting rejected. A recent report stated that 62% of engineering employers think that graduates do not offer the right skills. Is this statistic correct or is it that employers aren’t giving enough opportunity to see them?

Students are expected to tailor their applications to what they think are the most desirable skills for industry yet when they are rejected, they receive little to no feedback as to where they went wrong or how they could improve for next time.

VC-Bot was designed as an application support tool to effectively & professionally communicate students’ skills during the recruitment processes through datadriven decision making with the use of chatbot technology, video marketing strategies and a real-time dashboard to monitor your applications and recruiter activity, in the hope that students can learn what specific skills industry is looking for and personally develop on them.

— “I am looking forward to starting my graduate role with Capgemini Invent as a Brand & Experience Consultant in September and continue to develop my technology and systems knowledge.”

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RUAIRI GILDEA E: ruairi-g@hotmail.co.uk /ruairigildea-037000173

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SUPERVISOR: Melanie King

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PRODUCT DESIGN ENGINEERING PROJECTS

Design and manufacture of a garden/ agricultural product aimed at encouraging and inspiring sustainability and environmental awareness ETHAN GOODBODY E: ethan.goodbody@ hotmail.co.uk /ethan-goodbodya636a6172

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SUPERVISOR: Laura Justham

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Sustainability is a concept often overlooked during the design of products, yet with it being one of the most pressing issues in our current climate it is difficult to understand why this is the case.

The principle behind the project was to encourage and inspire sustainability and environmental awareness, with specific focus on engaging the younger generation. The concept was simple, enable users to utilise their biodegradable, household waste to grow new crops easily and efficiently.

Using market analysis, concept generation and subsequent concept development, the ‘gro planter’ was born.

The idea behind the planter is that it is hooked onto the inside of a balcony or railing, here the user can easily open the lid and deposit biodegradable waste

into the baskets within. The waste then decomposes and as it does so, holes in the base of the baskets allow for the nutritional fluids from this decomposition to pass down to the bottom section of the planter. Here, a two-tiered design is home to the user’s choice of above-ground plant, such as strawberry or tomato, where the nutrients are absorbed by the roots, consequently optimising growth, improving plant health, and rewarding the user over time with fruit and vegetables.

— “With the ever-growing need for a sustainable future, my plans are to help in the design and development of products aimed at making this a reality.”

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PDE PROJECTS 2021

Methods for the visual communication of complex analytical outputs This project aims to investigate methods to visually communicate complex analytical data through software elements.

It seeks to explore data analysis and Natural Language Processing, a subset of computer science and artificial intelligence which deals with machine interpretations and understanding of human language and the potential applications of new and existing software tools within the context of engineering/manufacturing.

The journey of utilising open-source Python packages for keyword extraction alongside personal programming contributions and software design will be documented to assess ways in which text summarisation can be used to visualise and improve understanding of data.

— “Once I have completed my degree, I plan work in technology either through Engineering or Data Science.”

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MAYU GREENAWAY-HARVEY E: mayuharvey@outlook.com /mayu-harvey

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SUPERVISOR: Diana Segura-Velandia

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PRODUCT DESIGN ENGINEERING PROJECTS

Toolkit to counter design biases

EMMA GREENHALF /emmagreenhalf

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SUPERVISOR: Mey Goh

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This project explores the design bias in society today, primarily against females, and what is being done and could be done to solve them, the conclusion, near to nothing.

There currently is a significantly small amount of data and research done looking at gender and design but there are countless examples where there are issues with a product’s design due to lack of gender consideration.

An example of this is that 62% of thirdtrimester pregnant women do not fit the standard seatbelt design and are therefore at much greater risk of injury when travelling in a car. As well as the fact that the most used artificial heart fits 80% of men and whilst only 20% of women, even though men and women are both equally at risk of heart problems.

The toolkit that has been created provides information and techniques to encourage a better inclusive design process for designers and engineers. It helps outline problem areas such as conscious and unconscious biases that we may hold and how the standards and stereotypes used when designing can be harmful.

This project is only the beginning of changing how gender is perceived and designed but gives a strong beginning to make a change.

— “Following my placement at Lockheed Martin, I am looking forward to completing my Masters in Product Design Engineering.”

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PDE PROJECTS 2021

To re-design the gynaecological speculum The Gynaecological speculum has had very few design updates since it’s conception in the 1800s. Patients find the speculum cold, threatening, medieval looking and uncomfortable, with a significant portion finding speculum examinations painful and not attending their regular screening appointments because of it.

Whilst there are a few different sizes of speculum, the clinician must estimate the most appropriate one for the patient.

There is no accurate method of doing this, and the effect of incorrect speculum selection can be traumatizing.

The main objective of this project was to design a product that was as functional as the speculum but that could be adapted to each patient, and looked comfortable, attractive and like it was designed for the user.

The solution was an inflatable product that has a small insertion diameter, like a tampon, that can be expanded once inside, and inflated only as far as the FLORIE patient is comfortable. This removed the need for the clinician to select the GUNERATNE correct size, as this speculum will adjust to the patient. There is also an E: florieguneratne@gmail.com option for the patient to operate the /florieguneratne inflation, which introduces more control into a situation where some patients ­— can feel incredibly vulnerable.

— “I will be undertaking another year at Loughborough University as a master’s student. I hope to go into design consultancy, developing products that will improve the lives of people, globally.”

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SUPERVISORS: Mey Goh Rebecca Grant

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PRODUCT DESIGN ENGINEERING PROJECTS

Development of an aortic valve scaffold with a natural histoarchitecture Valvular pathologies can be detrimental to valve function, with a common treatment being valve replacement.

Current valves have a multitude of issues EMILY HENN associated with them, including the risk of rejection and use of anti-coagulants.

E: emilyhenn23@outlook.com Tissue engineered heart valves (using a scaffold), are becoming an increasingly /emily-henn23 researched alternative, providing the opportunity to use patient-derived cells ­— and minimising the risk of rejection.

SUPERVISOR: Professor Sotiris Korossis

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This project aimed to develop an aortic valve scaffold suitable for cell-seeding and tissue engineering, with its design taking influence from the extracellular matrix (ECM) of the native valve - a complex of collagen and elastin fibres.

Two scaffolds were produced, a simple and a complex, reflecting the organisation of the fibres within the extracellular matrix.

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Each scaffold composed of many ‘unit ECM cells’ (UECs), which are repeatable units which were applied to a macroscale geometry model of the aortic valve to produce a mesh-like structure.

The simple model was designed to be 3D printed, and was done so using both material extrusion and material jetting, with material jetting producing a superior print with excellent resolution.

The final scaffolds both have the potential to be cell-seeded, if the right material was selected for use; materials such as hydrogels or collagen and elastin pose excellent alternatives to traditional engineering materials to use in this context.

— “After completing my MEng, I hope to pursue a career in the medical engineering sector.”

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PDE PROJECTS 2021

Ultraviolet sterilisation for common touch surfaces This project identified the sanitation capabilities of ultraviolet light. From this research a detailed product design specification was developed.

The design process involved multiple iterations and prototypes to develop the product into a fully functional sanitation unit with the capability of effectively sanitising daily contact items such as your phone, wallet and keys from bacteria and viruses (including coronavirus).

The design was then tested by a focus group to analyse the marketability and likeability of the product. Future testing will involve greater emphasis on UV sanitation efficiency and effectiveness.

— “Involvement in the development of innovative products (both design and process management).

With the future aim of developing a product and creating a business. ” —

JOSHUA HOSKEN jdlhosken.wixsite.com/uvclean E: jdlhosken@gmail.com /hoskenj

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SUPERVISOR: Elliot Wooley

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PRODUCT DESIGN ENGINEERING PROJECTS

Highly flexible, lightweight conformal body armour

ANGUS HOYLAND E: Angushoyland938@ gmail.com /angus-hoyland

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SUPERVISOR: John Tyrer

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As the world progresses technologically at an ever increasing rate, it seems strange that even the most advanced militaries still rely on body armour that has not developed much since the 1960s.

Even after 60 years of research the problems that have plagued ceramic plate armours since their adoption still persist and further advances come in ever more marginal gains.

This project looked to take body armour design in a new direction to try to provide a solution to the issue that doesn’t rely on ceramic plates nor is hampered by their disregard for the wearers comfort and protection against blunt force trauma.

The armour developed during this project is a silicon carbide and polyurethane granular armour; In which silicone granules have been set into a PU rubber with layers of aramid fibres spaced throughout.

This project developed an armour system that reduces the weight carried by the

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user whilst simultaneously providing superior armour coverage and range of motion. This design also provides the basis for a variable coverage armour system that would enable the user to almost completely box in the torso with armour coverage.

A backing for the armour compound consisting of a high evaporation rate spacer fabric and moisture wicking cloths has been selected that will ensure that this design keeps the wearer cool, comfortable, and hygienic for far longer than existing armour systems whilst adding very little weight or thickness.

— “My next step is to complete my Meng here at Loughborough before looking to become a design engineer in the defence or medical devices sectors” —

PDE PROJECTS 2021

Remote lab workstation using internet of things In recent years, the number of students enrolled in STEM subjects has increased significantly. This puts pressure on essential lab activities and negatively impacts the learning process. Remote laboratories are introduced as a solution to give students access to real experiments and allow them to carry out tasks from anywhere in the world through the Internet. This project aims to investigate and develop an IoT platform that allows the remote control of lab experiments.

I developed ArduinoAutoGUI, a novel IoT platform that auto generates web graphical user interface for an Arduino controlled experiment. It allows lecturers to easily set up an experiment rig and configure the autogenerated graphical interface either directly from Arduino code or through a web application for advanced styling options.

The system includes a webcam, collaboration features for students, and data can be inspected live or downloaded for retrospective analysis.

To showcase the capabilities of the platform I built an inclined plane experiment rig and tested the system. Multiple students can join an experiment, control it, and chat via messages or use their microphones to collaborate.

— “After completing my studies at Loughborough, I would like to pursue a career in the Tech industry as a design or software engineer.”

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MARA ILIE E: m.ilie-17@student.lboro.ac.uk ilie.mara@yahoo.com /marailie8a9748158

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SUPERVISOR: Antony Sutton

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PRODUCT DESIGN ENGINEERING PROJECTS

The effect of topical force on applied to various tissue structures

OLIVIA JEFFRIES E: Ocjeffries@gmail.com /olivia-jeffries

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SUPERVISOR: Yang Liu

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If an autoinjector delivers a drug into the wrong tissue, the consequences can be fatal. Therefore, it is vital to understand how the body behaves when an autoinjector is activated upon contact with the skin. This has an effect on the tissue structures and must be optimised to ensure the drug is delivered into the correct tissue. The project was sponsored

by Oval Medical Technologies (Oval), an autoinjector medical device company.

Topical pressure was found to have an effect on tissue compression, which compresses as the force is increased until maximum compression is reached. Thicker tissues compress to a greater extent than thinner tissue, showing that tissue thickness is more consistent at maximum compression.

Furthermore, muscle accounts for the majority of tissue compression when an autoinjector is activated.

An ultrasound attachment was designed simulating the ArQ Skin Sensor surface area, an Oval autoinjector. The attachment was then used in a clinical study to assess tissue compression of the subcutaneous tissue and muscle in the thigh. A Finite Element Analysis model was built simulating different tissue thicknesses, different forces and different size load points on subcutaneous tissue and muscle.

— “I would like to pursue a career in the medical device industry.

Working to improve the user experience and effectiveness of the products. ” —

PDE PROJECTS 2021

Design of a non-invasive hypoglycaemic detector Type 1 diabetics must continually monitor and control their blood glucose levels and perform multiple insulin injections a day.

Additionally, there is a 93% likelihood that Type 1 diabetics are more susceptible to develop dementia. As a result, there is a high chance that Type 1 diabetics over the age of 65, who also suffer with dementia, will frequently have hypoglycaemic attacks (low blood sugar levels, below 4mmol/L) due to administering too much insulin or forgetting to eat. Without prompt action, these attacks can lead to unconsciousness and organ failure.

The aim of the project was to design a product which would be able to alert the user to an imminent hypoglycaemic attack without piercing the skin, unlike the competitor’s product. By monitoring trends in the body’s heart rate, sweat production, temperature and movement, the developed product can determine if the user is having a hypoglycaemic attack.

Consequently, the user and their emergency contacts will be notified, allowing enough time for the user to consume food high in sugar to restore blood glucose levels.

A wearable hypoglycaemic detector would not only give users’ their independence back but would give family and friends peace of mind knowing their loved ones are safe. Furthermore, hypoglycaemic attacks cost the NHS £13 million per year so the product will reduce the pressure on the NHS as there would be less cases of severe hypoglycaemia.

— “To pursue a career as a Design Engineer and work on a wide range of projects in the consumer and medical sector. ” —

HOLLIE JENNINGS E: Holliejennings73@gmail. com /hollie-jenningsdesignengineer

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SUPERVISOR: Paul Maynard

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PRODUCT DESIGN ENGINEERING PROJECTS

The design of a lower limb prosthesis to be used by a growing and active child

ERIKS KEHRIS E: kehrise@gmail.com /eriks-kehris45194415b /cycledelicuk/?hl=en-gb

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SUPERVISOR: Sammy Wilson

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Children needing prosthetics quickly outgrowth them; the rapid obsolescence of prostheses limit a child’s confidence and familiarity. The introduction of a “growing” prosthetic has potential to eliminate four replacement cycles, facilitating the child’s understanding of the device and thus increasing confidence in use. The prosthetic system had to consider anatomical changes, activity levels and associated behaviours to allow natural gait initiation.

A range of anthropometrical and technological research had to take place to identify systems and dimensions that would be functional, lightweight and safe to use by the child. Conceptual designs were generated, thus allowing the final transfemoral prosthetic to be manufactured using mechanical, pneumatic and hydraulic extension mechanisms.

Using a one-off protype, 7.8% in cost savings were made over 6 years, in addition to numerous associated physical and psychological benefits experienced by the child as a result of a new transfemoral prosthetic device.

Scan the QR code to see the CAD design of the leg and its extension mechanisms.

— “Enter the frame design sector within the cycling industry within the next few years, either in the Netherlands, US, or Taiwan.”

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PDE PROJECTS 2021

A novel device to improve sustainability in the home Improving sustainability within the home through reducing impact on the environment is becoming more important for families. One of the biggest problems is the amount of carbon dioxide being released into the atmosphere. In the home water usage and wastage are two of the largest contributors. The bathroom is the main source for water use, especially the bathtub, which is mainly used by families. This problem has resulted in the need for devices which will help families reduce their environmental impact.

Therefore, the main aim of this project is to design a retrofittable device which reduces water usage and improves bath time safety for children.

Firstly, a literature review was carried out to understand the implications of water usage in the home, in particular bathrooms and bathtubs, the safety implications of bathtubs. Market research was conducted through surveys and focus groups.

This led to the creation of the product

design specification which was the starting point for the ideation of multiple design concepts. One of these was selected to be further developed using engineering science and prototype testing to create a final design iteration.

HOLLY LANGSTON Overall, the project’s main aim was achieved through the development of E: Hollylangston99@gmail.com ‘Thermae Tots EcoDivider’ an adjustable bath divider which reduces water /holly-langstonusage in the bath for children by 30% 27b74b158 and increases bath safety for children using a thermochromic liquid crystal ­— thermometer.

SUPERVISOR: — “After completing my PDE BEng, I will be searching for my first graduate employment opportunity this summer and my ideal opening would be a product based role in the sports industry. ” —

James Colwill

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PRODUCT DESIGN ENGINEERING PROJECTS

Combined kitchen composter and mushroom grower

JASMIN MALEK E: Jasminmalek@outlook. com /jasminmalek

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SUPERVISOR: IAN GRAHAM

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Mushrooms are widely known for their distinct taste and impressive health benefits. However, growing mushrooms at home is a very daunting concept to many people, and there are often doubts about the hygiene of the process or whether it is even feasible on a small scale. This is exacerbated by the fact that there are currently no existing mechanical solutions for the complete cultivation of mushrooms at home.

In reality, the requirements and safety of mushrooms are comparable to those of plants, whilst the rewards are even faster and incredibly nutritious.

The most important element of mushroom growing is having a good ‘soil’, or substrate, to grow them in. Using this product, users can turn household waste into a viable mushroom substrate, by adding fruit/vegetable scraps, shredded paper and coffee grounds/tea bags to the system along with some water and bought in mushroom spawn. The product does the rest of the work, by intelligently

combining these inputs in just the right ratios for the type of mushroom that will be grown. This mixture then passes down into a chamber, where it is incubated in a chamber with carefully controlled conditions, until the mushrooms are ready for harvest.

The function of this design encompasses everything from the balancing of mushroom substrate to the complete control of fruiting conditions, all with minimal user effort but a comprehensive education in the process.

— “I am going on to my placement year with Buhler UK, but am excited to keep developing this idea and will hopefully build it one day!”

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PDE PROJECTS 2021

Design and development of a solar battery cooker (AC version) This project discusses the design and development of an AC Solar Battery Cooker for the MECS project. The need for modern, sustainable cooking solutions in low-latitude countries, with developing economies is substantial.

Malawi is an example of a country in need of sustainable cooking solutions as they make up 13% of the global population without access to modern electricity and part of the three billion people worldwide, who are still reliant on biomass to cook using three stone fires. A solar battery cooker can utilise readily available solar energy to power modern cooking appliances. However, as nations such as Malawi develop, it is our responsibility to ensure they make more sustainable choices than the larger economic nations have done. Installing modern cooking solutions that run off greener sources of electricity and operate far more efficiently than current cookers will improve the health and quality of life of the users whilst having a global impact on the environment.

This report details a solution for a solar battery cooker where research has been conducted into the accessibility to clean cooking in Malawi, solar PV modules and batteries. The system uses 2 to 3 solar PV modules to charge a LiFePO4 battery which in turn powers an AC cooker.

The cooker design involves an electric pressure cooker (EPC) and an electric hotplate which are controlled using relays to ensure both devices can be heated whilst only one is powered. The testing of the cooker proved it was successful in cooking a meal on two appliances whilst only outputting a maximum of 1100W.

— “I plan to gain experience in the design engineering field in a broad range of roles. Eventually I would like to work in the sustainable engineering field or consultancy.”

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GEORGE MANGNALL-GREEN E: Georgegreen4159@ outlook.com /george-mangnallgreen-64aaa617a

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SUPERVISOR: Richard Blanchard

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PRODUCT DESIGN ENGINEERING PROJECTS

Vehicle driver’s stress level detection

ALEXANDER MANNING E: ajm.manning01@gmail. com /alexanderjmanning

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SUPERVISOR: Sijung Hu

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The project examined the feasibility of producing a steering wheel to detect, monitor and reduce the passive stress of the driver of a domestic vehicle, prior to self-diagnosis.

By measuring the heart rate variability of the driver, physiological factors could be measured non-invasively using contact photoplethysmography and an opto-electric sensor behind the wheel.

This project pioneered research into the viability of using this type of sensor technology within the automotive industry and given the versatility of opto-electronic sensors in particular, this project could pave the way for early detection, and thereby eradication of, different stressful scenarios that are not just limited to transportation.

The primary features of the steering wheel included four communicative LEDs, ambient light to stimulate nondrowsiness, a contact sensor around the rim of the wheel and ten smart buttons that can be programmable for different users. The design was also compliant with ISO standards and EU legislation and considered the marketability of the proposed brand, Spartan Steering Systems.

— “Continue research into biometric sensors and data analytics” —

PDE PROJECTS 2021

Energy analysis of low carbon heating for homes and small commercial units The project was to investigate low carbon heating solutions for domestic space heating in the UK. In order to conduct comparative analysis between gas boilers and renewable technologies I developed a excel model which included an analysis factor: Real World Cost (RWC).

This is a method for complete analysis of a heating systems feasibility and is based on a single monetary value of all Financial, Environmental and Practical benefits. The model produces annual costs, cumulative CO2 emissions, cumulative RWC, Carbon intensity of heating and RWC of heating data for gas boilers, ground/air sourced heat pumps and biomass boilers.

The model explores the nuances of domestic space heating and the affect a wide number of variables such as location, house type and garden space

have on determining the optimum heating system for a property. Analysis of data from the model concluded that renewable technologies could reduce emissions up to 94.4%. In general, it was found that a low carbon solution would be feasible for every house type and renewable technologies nearly always have a lower Cumulative Real World Cost compared with gas if the owner is staying in the property for more than 7 years.

The report concludes definitive optimal low carbon heating solutions and the benefits replacing gas with these could have nationwide.

Additionally, a selection of hyper specific case studies were investigated to explore the finer details of low carbon alternatives as well as heat recovery integration, producing the most efficient heating systems.

— “After University, I hope to either do a PhD in Renewable energy and work doing research and development projects in the sector, or work as a Design Engineer designing medical devices. ” —

FREDDIE MARRIS E: freddiejmarris@gmail.com /freddie-marris-a13aa617a

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SUPERVISOR: Prof. Graham Hargrave

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PRODUCT DESIGN ENGINEERING PROJECTS

The design of a lower limb ankle prosthetic used by a growing and active child

WILLIAM MARTIN E: willjmartin22@gmail.com /william-martin83168a15b

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SUPERVISOR: Sammy Wilson

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Lower limb prosthetics have been used throughout history to help those affected by limb loss to be able to walk again, and advances in technology have allowed for the replacement of a simple wooden leg with prosthetics designed to mimic the biological function and biomechanics of the human gait. To mimic the biomechanics and function of a limb, the prosthetic device must be tailored to the user. This presents a problem with child amputees since they are constantly growing during their early years, doubling their birth height by 3-4 years old and growing at a rate of 5cm a year until puberty. Inaccurate length and fitting of a prosthetic can lead to incorrect development of limbs as well as an imbalance affecting their biomechanics: such as an alteration in the kinematics of the lumbar spine. This can lead to child amputees having their prosthesis changed every 6-12 months.

The project involved the identification

of the problem, concept generation and testing of an adjustable child prosthetic that is low cost, lightweight and easily available. Prototyping of various designs using 3D-Printing allowed for testing such as tensile and compression testing, durability testing, Finite Element Analysis as well as testing the function of the prototype using a human user and a specially designed test rig. The results of the project were a fully 3d-printed modular design, that is easily adjustable and uses low-cost materials and manufacturing.

— “After graduating I aim to further my studies on an engineering masters and hope to further explore the prosthetic and sport engineering industry” —

PDE PROJECTS 2021

Improving the end-of-life profile of a pump dispenser Pump dispensers are difficult to recycle with the guideline from WRAP (Waste and Resource Action Program) detailing to not recycle, but instead to throw into landfill causing unsustainable attributes. Pump dispensers are composed almost entirely of plastic apart from a metal compression spring that returns the head of the pump back to its original position once its pressed. This mixture of materials causes issues with recycling due to complicated methods required to separate them into their pure streams

A proof of principle prototype was produced that was able to return the pump head back to its original position by utilising a plastic spiral spring. This system was compared functionally and sustainably to an existing pump dispenser through force analysis and life cycles analysis software, respectively.

The LCA showed that a global warming impact reduction of 38.5% per pump dispenser produced could be expected if companies implemented it instead of their current unrecyclable dispensers.

My project improves the end-of-life profile of a pump dispenser by implementing an all-plastic system, with the key innovation being the replacement of the metal compression spring with a plastic alternative. This allows the pump dispenser to be recycled globally, something no pump dispenser has achieved yet.

— “Before my final year of masters, I will be doing a placement year at Kohler Mira working as a design engineer intern.”

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SAM MASON E: S.r.c.mason-18@ student.lboro.ac.uk /sam-mason-434aa717a

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SUPERVISOR: Patrick Webb

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PRODUCT DESIGN ENGINEERING PROJECTS

Utilising emergent manufacturing methods to devise improved corrective apparatus for leg length discrepancies

KAI MENDES E: KMendesBusiness@ outlook.com /kaimendes

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SUPERVISOR: Dr. Simin Li

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Leg Length Discrepancy is a condition where one leg is shorter than the other.

It comes with health problems e.g. lower back pain, scoliosis, stress fractures and a poor gait. Its correction involves either invasive or non-invasive methods e.g. surgery or orthotics to equalise the leg lengths.

The orthotics (heel lifts and shoe lifts) are popular options which help, but come with problems: For shoe lifts, patients do not want to use unsightly outer orthotics that require permanent modification of a relatively small range of compatible shoes.

Prototyping and testing via quantitative data analysis (ground reaction force in gait and centre of pressure in standing via force plates) and qualitative methods (Timed Up and Go test assessed by 8 NHS clinicians) was conducted.

It was shown that the produced additive shoelift corrects well, with 6 out of 8 NHS clinicians agreeing that it treats better than existing NHS heel lifts, alongside being easy to fit, bespoke, quick to manufacture and aesthetically pleasing.

— “Continued development and actualisation of the additive shoe-lift, alongside further exploration Is it therefore possible to use emergent of the medical and consumer design/ additive manufacturing to create a better engineering sectors to find what orthotic? By utilising CAD and 3D printing I am most fulfilled creating.” (material extrusion), this project aims — For inner-shoe heel lifts, they often cannot provide full correction due to constraints of the inside of the shoe, and do not support the entire foot.

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to make an orthotic design that is easier to produce, is more aesthetically pleasing and can support a range of shoes.

PDE PROJECTS 2021

Designing of low cost Covid-19 gas mask for first attenders The pandemic that occurred in early 2020, due to the widespread of COVID-19, has drastically proven the need of a cheaper and better gas mask hood that can be used by first aiders when trying to prevent the further spread of the disease.

The gas mask hood would potentially be used by unconscious injured or vulnerable people in need of protection when they are in a present of an environment that might potentially be affected by Coronavirus.

The research done on the existing products, reviewed that some of the masks used by the first aiders made it harder for them to perform their jobs properly due to the masks not offering a full protection, taking longer to put on and expensive. As a result, many first aiders end up contracting Coronavirus.

A material research was also done, to review the best materials that could be used on the hood was PFA

(Perfluoroalkoxy) which is a Fluoroplastic that has properties such a high melting point and a very low crinkling noise level.

The prototype that was developed was tested in 2 ways: how to wear the gas mask hood and how it performs. Due to the pandemic, it was not possible for participants to be used or to use a test facility. However, other tests methods were used in order to determine the functionality of the prototype. The results showed that the prototype met most of its aims and there were just a couple things that needed to be improved for it to manufacturing ready.

— “After graduating, my career plans for the future are for me to be a Junior Product Designer at a smaller engineering company ” —

MUTSA MARTIN MUGADZA E: martinmugadzajnr@ gmail.com /mutsamartinmugadza

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SUPERVISORS: Professor John Tyrer, Hendrik Versteeg

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PRODUCT DESIGN ENGINEERING PROJECTS

The design of a sustainable system to improve indoor air quality.

BAHAR NOHANI E: B.nohani-18@student. lboro.ac.uk /baharnohani

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SUPERVISOR: Dr.Melanie King

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We spend between 60-90% of our time in airtight buildings designed to minimize the operating costs associated with heating and cooling the environment.

Indoor air can be 2-5 times more polluted than outdoor air due to synthetic building materials, furnishing and products that are common in occupational buildings.

The synthetic materials ‘off gas’ harmful chemicals such as Total Volatile Organic Compounds (TVOCs), associated with numerous health impacts. In the short term, pollutants can irritate the lung lining, triggering respiratory symptoms and placing stress on the cardiovascular system. This contributes to ‘Sick Building Syndrome’ which occupants have experienced regularly since the design of airtight buildings in 1970s. Long term exposure can contribute to a greater risk of cancer and onset neurological diseases.

Natural Purifier is a sustainable system, that uses plants as the main tool to reduce the harmful chemicals in an indoor air environment by 60% after a single pass through the system.

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This technology uses the products of Photosynthesis - oxygen, sugars, and protein - to enhance the activity of beneficial microbes in the roots that oxide TVOCs in the contaminated air without producing harmful byproducts in the process. The designed system extracts the indoor air and passes it through the roots of the plants where the contaminated air is purified, cleaner air is then dispersed out of the system into the environment.

— “I will be joining Textron for a Design Engineering placement next year, before returning to Loughborough to complete my masters in Product Design Engineering.”

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PDE PROJECTS 2021

Improving the recyclability of sports and exercise equipment: industrial sports ball recycling line The sports equipment manufacturing industry within the UK has been growing for the last 10 years with just over £400 million in product sales in 2019 alone.

The impact of the COVID-19 pandemic has been predicted to accelerate this growth even further with more people exercising at home. This project has been undertaken in order to address the current lack of consideration for these sporting goods at the end of their user life by proposing an industrial recycling line focused on sports balls.

It was determined that a viable recycling line could be established in order to accommodate for downcycling material avenues as outputs would likely be of <95% purity. Whilst this does mean the system would achieve the project aim, it does not create a completely closed recycling loop for material. This provides scope for further work either in improving the design on the line to achieve higher purity groups; or the redesign of sports balls to improve their recyclability.

To approach this issue, a review of different sports equipment and current methods/ research was completed. This was combined with an insight into material and chemical composition gained from a product sample group disassembly.

Recycling opportunities for these materials was then considered. This resulted in the design of theoretical industrial scale recycling line to process sports ball materials and give outputs viable for secondary manufacturing markets.

— “After a placement at Renishaw, I plan to return to Loughborough to complete a masters degree in PDE. I hope to then move into a career centred around sustainable design.”

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FERGUS NORTHFIELD gusnorthfield374c. myportfolio.com E: gus.northfield@gmail. com /fergusnorthfield-410156109

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SUPERVISORS: Shahin Rahimifard, Radmehr Monfared

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PRODUCT DESIGN ENGINEERING PROJECTS

Automated manufacturing demonstration

KEATON ODLING-THOMAS. E: Keatono-t@hotmail.com /keaton-odling-thomas

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SUPERVISOR: David Hutt

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The course leader for Manufacturing Engineering at Loughborough University requested a demonstration for open days that draws prospective students towards Manufacturing Engineering, they wanted the demonstration to be based on automated manufacturing and incorporate some aspect of automation.

The aims established from this request were to design and create an informative and visually appealing demonstration that includes aspects of Automated Manufacturing.

Using research on automated manufacture and visual demonstration success factors, alongside customer analysis and customer consultation, a design specification for the request was formulated. Using this specification, innovation, and design principles such as controlled convergence, the request from the customer was transformed into a set of ideas.

These ideas became concepts, and the concepts became a design.

The design includes a robotic arm, a circular conveyor belt operating on a motorised gear system, a ramp fed dispensing unit and a colour sensor, all battery powered and controlled by Arduinos. The design was manufactured, assembled, and programmed, forming a fully functional prototype.

— “I am aiming to finish my Master’s in Product Design Engineering here at Loughborough. I then hope to have a career in toy design and manufacture.”

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PDE PROJECTS 2021

Using NX machining line planner to create a process plan for multiple setup machining processes The project is “Using NX Machining Line Planner to create a process plan for multiple setup machining processes.”

The project mainly went into the utilisation of Siemens Machine Line Planner. This project covered a lot of other parts of CAM manufacturing that can be found in the Siemens NX program.

Methodology entailed making a process plan in NX Machine Line Planner and by making a student guide. The main findings are the usefulness of the software. The software on average can help users to make multi-setup machining lines that can be adapted for different machinery. The student guide use and expanding the user base of NX MLP by making them more comfortable.

Also, the use of CAM templates and PMI are integrated into the final manufacturing. CAM Templates is a useful tool that allows the user to make predetermined parameters, just like tool specification and specific operations.

A brief conclusion is that NX MLP is a useful tool and can be on average a lot more useful than traditional methods.

The use of NX MLP is easy after the user TIMMY gets a grasp of how it works. NX MLP CAM manufacturing and digital twins OGUNKUNLE could be the long-term future of CAM manufacturing. More companies are in E: timmyogunkunle@gmail.com cooperating with a digital twin system /timmy-ogunkunle and software like the NX MLP are part of those systems as it can show factory lines ­— in a digital space. A youtube video with the SUPERVISOR: step by step guide for students is online to show how to utilize NX MLP. Amin Tulemat

— “After finalising my PDE degree at University, the plan is to work in the Design Engineering field. Would love to go into automotive design, in large global companies like Tesla and BMW.” —

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PRODUCT DESIGN ENGINEERING PROJECTS

New materials for 3D printing electronics

DAISY OSSAI E: ossaidaisy@gmail.com /daisy-ossai-499747158

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SUPERVISOR: Daniel Engstrom

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In the past few years, Fused Filament Fabrication (FFF) has been implemented for the manufacture of functional prototypes for microwave and radiofrequency applications. There is potential for the development of novel ceramic-polymer composite filaments with superior dielectric properties for the manufacture and miniaturization of microwave devices.

This research project investigated and reported the dielectric properties obtained from the fabrication of composite materials manufactured with Barium Strontium Titanate (BaSrTiO3BST), and Acrylonitrile Butadiene Styrene (ABS) for use within microwave and radiofrequency devices. The dielectric properties considered, were the relative permittivity (εr), loss tangent (tanδ) and Q×f (GHz) for all composite materials produced. Ten composite filaments were successfully produced and used to fabricate 3D-printed specimens. The dielectric properties were obtained with

a Split Post Dielectric Resonator (SPDR) and material properties with density tests and Scanning Electron Microscopy. The best composite material was the 100wt.% BST filament, with a permittivity value of 5.83/±0.77 and dielectric loss tangent (tanδ) of 0.0072 ±0.0002 .

The obtained dielectric values, were superior in comparison to conventional polymers for Fused Filament Fabrication (FFF) (εr ≈ 2–3 at microwave frequencies).

Further studies can be performed on the BST-ABS material combination for implementation within real components and prototypes.

— “Following Graduation, I will be joining HSBC as a graduate Technology Analyst.”

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PDE PROJECTS 2021

Industry linked project: tranquil plants This project is in collaboration with Tranquil Plants, a Kokedama Plant manufacturing company based in Loughborough. Kokedama is a Japanese traditional method of wrapping the roots of a plant in moss to form a natural pot for the plant.

The primary aim of the project is to design an installation incorporating Tranquil Plants’ products which meet the companies specification, in particular having artistic merit and involving suspension. The key objectives being to reach an approved final design, realise elements from the design, and validate them through physical and mathematical testing, whilst satisfying the client throughout.

The project focused on two main installation designs, one for display within Kew Gardens and one for display within the Loughborough University. The designs both involve multiple elements including a water suspended feature, a concealed hanging mechanism, a height changing mechanism, incorporating lighting

and mist. The impacts of COVID-19 prevented the full installation to be completed, however, the design was fully validated and visualised.

The aim, objectives and deliverables were met over the course of the project.

The client was very pleased with the work completed throughout, which presents opportunities for developing new product lines, with financial benefit for the company.

— “I am hoping to complete a placement year prior to returning to Loughborough University to study for a Masters in Product Design Engineering. ” —

ROXANNA PARKER E: mcsploxo@gmail.com /roxanna-parker

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SUPERVISOR: Andy Gleadall

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PRODUCT DESIGN ENGINEERING PROJECTS

Taming the heliodon: remote lab demonstrator for sun position visualisation

SHREEYA PATEL E: shreeyapatel1998@ gmail.com /shreeya-patel

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SUPERVISOR: Tom Betts

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The aim of the project was to design and build a sun position experiment to be used as a teaching tool for distance learning students. This took the form of a heliodon, which is a device to change the relative angle of a light source to a scale model and a graphical user interface, with a camera feed, for remote access.

A user interface was created using LabVIEW. This allowed the student to input the variables required in a user-friendly way and view the footage from a camera fixed to the model platform. The LabVIEW interface sent the relevant information to the Arduino via Serial Communication.

The heliodon device was designed to be compact and fit in a laboratory. The model platform has two rotational degrees of freedom to move to all the sun positions necessary. It was constructed using a combination of laser cut acrylic and MDF parts, 3D printed components and machined parts.

These aspects were all brought together, along with a scale model of Stonehenge and a stage lamp for the light source.

This resulted in a complete remote heliodon system.

The heliodon model platform was adjusted using two stepper motors controlled by an Arduino Uno and two A4988 motor driver boards. The sun position algorithm from the module literature was implemented within the code to drive the motors to the necessary position.

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— “After completing my masters year, I hope to get a graduate role in R&D that allows me to use the skills I have learnt during my time at Loughborough.

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PDE PROJECTS 2021

Personalised text input device The project presents the design and development process of a hand-held personalised chorded keyboard for onehanded users. The developed design takes full advantage of the benefits of 3D printing technology, being affordable and fully customisable in terms of size, key span and aesthetic appearance.

The proposed chorded keyboard is a compact, portable and easy to use product, having a manufacturing cost 10 times less than the average market price for commercial chorded keyboards.

The digital parametric design is used in combination with a series of hand measurements and mathematical calculations to enable size customisation and device personalisation. Therefore, the overall size and button span can be adjusted for each individual user, making the product unique among other commercially available chorded writers.

The conducted work resulted in a number of outputs that exceeded the objectives set at the start of the project.

These included the production of a fully functional device, a conceptual design for the home assembly kit, a parametric keyboard design compatible with the established size customisation strategy and a self-training game tutorial application.

Further work will be conducted to improve the capabilities of the chord writer in order to surpass the full capabilities of a standard keyboard.

GEORGIANA PAUL E: georgianapaul@icloud.com /georgiana-paul

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SUPERVISOR: Peter Kinnell

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— “I am very much looking forward to starting my career as a design engineer. ” —

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PRODUCT DESIGN ENGINEERING PROJECTS

The implementation of augmented reality as a training tool to enhance flight safety for pilots

GEORGE PICKARD E: g.pickard@student. lboro.ac.uk /george-pickard03099517b

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SUPERVISORS: David Whalley, Changqing Liu

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Some of the current flight safety methods available today suggest that there is disparity in the type of training and exposure received between private and commercial pilots. Although the current flight training across all types of license ratings are very strict in order to minimize the risk of a potential flight catastrophe, pilot error still accounts for around 80% of all air accidents. This project looks at the possibility of extending some aspects of the training and exposure to private pilots. Taking full advantage of the endless capabilities offered by technology today, which are not only widely accessible but also adaptable.

An analysis on the viable types of digital display technology narrowed down the types of technology that could be used into two different categories. These two were projecting and reflecting, the latter being used due to complications and limitations in the former. A user interface was built on windows forms and ported

across to the device, which allowed for full customization of the simulation by varying the type of images, the sequence and the duration. An experiment was then constructed which aimed at analyzing the prototype across a range of vertical and horizontal angles. This prototype managed to combine some of the advantages of a virtual simulator with the real experience of flying, but would need additional development in order to be a commercially viable product.

— “After this year, I would like to apply the skills learnt throughout my time at Loughborough into a field which focusses on the design and engineering of consumer products.”

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PDE PROJECTS 2021

Design a product to reduce anxiety and/or enhance wellbeing This project aims to design a product to reduce anxiety and/or enhance wellbeing, which will be achieved within three stages. It begins by delving into the causes, symptoms, and effective treatments available to combat the various mental health conditions. An effective method of treatment was selected, which was made more portable by integration into a product. This proposes to make a reputable form of treatment quick and easy to access, enabling improved management of symptoms within a busy schedule. To arrive at a final product, an extensive design process explores different avenues of increasing the treatment methods portability, alongside improving its effectiveness at providing symptom relief. This is runs in parallel with a rigorous prototyping process, which tests, validates, and further develops aspects of the product key to its success and feasibility.

The project concludes in presenting a well-developed, viable product proposal, which specifically targets the needs of young professionals with generalized MATTHEW anxiety disorder. It is built specifically around their needs, harnessing the PRITCHETT breathing practice ‘box breathing’ to provide relief from symptoms in an E: matthewpr99@gmail.com inconspicuous way, whilst on the go. /pritchettmatthew It proposes a core product idea backed by several prototypes, alongside extensive ­— manufacturing plans and costings.

— “Next year I will be completing a 12-month placement with Jaguar Land Rover in their Design Technical - Studio Engineering team.”

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SUPERVISOR: Paul Maynard

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PRODUCT DESIGN ENGINEERING PROJECTS

Understanding climbing performance with a smart climbing hold

SAM RADFORD E: shwelis@icloud.com /sam-radford6a5aa817a

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SUPERVISOR: Pablo Ruiz

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The project focused upon computational simulations to deliver a scientific testing tool for an instrumented strain gauge plate which measures the forces and moments upon climbing holds.

The tool can measure, analyse, and display specific climbing performancerelated metrics, based upon the 3D force and moment readings gathered by the device, calculating the climber’s finger positioning upon a climbing hold as a function of time. Quivers plotted the resultant force of each point of contact recorded.

For ease of visual inspection, the points were categorised by distance from the original coordinates into colours: Green, within 1mm; Yellow, 1 – 2.5mm; Red, 2.5 – 10mm; Black, unacceptable, more than 10mm away from the original coordinate.

The project met its main deliverable of producing a tool capable of calculating a climber’s point of contact upon the hold as a function of time, allowing for phenomena such as muscle tremors or specific hand movements to be detectable within the force and moments readings in future work.

— “Aspirations to move into Sports Performance Analysis, particularly football, having made prediction models using the Poisson distribution over my time at university. Currently looking for an internship or placement for the new season. ” —

PDE PROJECTS 2021

PC interface for arm prostheses Most commercially available prosthetic limbs are not designed to interact with computer hardware, and thus many prostheses users struggle with using computers effectively. I have designed and made a prototype product that will directly translate the user’s muscle movements to computer inputs, eliminating the need to physically interact with a computer with a prosthetic limb. It uses a gyroscope to map arm movements to the mouse cursor and a myoelectric sensor to read muscle contractions which allows the user to carry out several clicking operations. The prototype works and registers muscle contractions to an accuracy of 66%. With further development in myoelectric technology and refinement of my design I am certain this will become a viable commercial product.

— “I’m looking to get a job designing and making smart prosthetics and continue the work I have done in this project.”

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JAMES RAYMER /UCiu9ew1CMEvWd3k V6zRnPHQ E: Jraymer9800@gmail.com /james-raymer-4b0748158

­— SUPERVISOR: Ian Graham

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PRODUCT DESIGN ENGINEERING PROJECTS

Agricultural equipment design to improve the ergonomics of the rice growing process for women in India JOSHUA RILEY E: joshuariley2511@gmail. com /in/joshuariley-

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SUPERVISOR: James Colwill

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In India, when uprooting crop during the rice growing process, female labourers, who are typically delegated manual tasks, are required to operate in unergonomic positions for extended periods, inducing excessive stresses on their neck, back, legs and knees. This has led to the prevalence of musculoskeletal disorders, such as rotator cuff tendonitis and knee osteoarthritis. Additionally, due to the inefficiency of current practices in India, demand for rice produce significantly exceeds current supply levels.

The solution developed enables the user to work in a prone operating position which, combined with cushioning at critical areas, alleviates stresses on the neck, back, legs and knees. This improved operating position, along with design features that streamline the uprooting process, were proven to increase worker’s productivity.

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Meanwhile, force testing and biomimicry analysis were performed to ensure the device’s suitability for the irrigated use environment. The product primarily consists off locally sourced bamboo and has been designed so that it can be manufactured and assembled in India, providing jobs for local communities.

— “After completing my Masters in Product Design Engineering, I would like to pursue a career in Design Engineering” —

PDE PROJECTS 2021

Design of a product or device to reduce household food waste Milk waste is the third most wasted food group in the UK by weight (330,000 tonnes). 90% of this is produced by households, costing around £250 million and producing up to 350,000 tonnes of CO2. The main cause is the bad habits and behaviours surrounding milk usage in households. Such habits include accidentally leaving milk out of the fridge, storing milk above recommended temperatures, and not using the milk before it expires.

This project demonstrates the design and development of Milk Monitor, a device which targets bad habits to help reduce household milk waste. This device clips to a milk bottle with an insulative band and measures the environmental temperatures that a milk bottle experiences. It then provides visual and audible alerts and feedback to the user to ensure consistent and correct storage temperatures, and full consumption within the expiry date.

Testing of the device revealed a 20% slower temperature increase in milk with the addition of the insulative strap.

Additionally, by alerting the user that the milk is outside of the fridge, the device ensures that the temperature of the milk does not increase more than 1˚C above stored temperatures. Furthermore, the device alerts made the user more aware of correct fridge temperatures and reminded the user when they need to finish the milk. During the tests, the device was effective in reminding and prompting the user to maintain positive milk habits.

— “I am hoping to do a placement next year, then finish my Masters degree in Product Design Engineering, and afterwards, pursue a career in the Product Design industry.”

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DAVID RIMMER E: djrimmer99@gmail.com /david-rimmer50999517b

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SUPERVISOR: Elliot Woolley

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PRODUCT DESIGN ENGINEERING PROJECTS

Device to assist sitting down and standing up from a dining chair

CERAN SANTHAMOORTHY E: ceran.santha33@gmail. com /ceran-santhamoorthy897aa717a

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SUPERVISOR: David Hutt

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Getting in and out of chairs and sitting/ positioning comfortably can be difficult for elderly people or those with disabilities.

This can be due to difficulty in balancing, restricted space, or a lack of places to hold for support, and can be particularly problematic in dining chairs at home.

For carers, the task of helping them can be difficult and lead to injuries. Commonly develop illnesses such as arthritis and musculoskeletal conditions, affecting their ability to perform the motions required without straining their joints.

It was found that a dining chair will require lifting and repositioning when sitting at a table, in which these actions required can have a severe negative effect on the user’s arm, hand, back and knee joints.

This project aimed to design and develop a seat assist device that can easily attach and detach from a chair, enabling the user to comfortably sit down, stand up and move closer to the dining table without needing to lift or reposition the dining chair.

The research and concept developments led to the successful creation of a seat mechanism that independently moved a user 230mm forward and rotated anticlockwise and clockwise, allowing the user to move closer to the table and get out from both sides of the chair without needing to reposition it. This mechanism was successfully prototyped, showing the design feasibility and future potential of this product to be developed further.

— “After completing my Master’s Degree in Product Design Engineering, I hope to pursue a career within the automotive industry as a quality or design engineer.”

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PDE PROJECTS 2021

Solutions for a ‘smart’ campus: ‘smart’ mobility The rapid growth of the world population alongside the constant high demand is resulting in alarming levels of climate change and natural resources depletion.

Given these challenges, there has been an increasing concern with the environment over the world and many companies and communities are becoming more determined to choose for the sustainable options. Urban mobility is one of the main sectors that is leading the revolution towards a more sustainable future, by the implementation of an efficient public transport system to solve part of the congestion problems.

Single car use at Loughborough produces 265 tonnes of carbon dioxide alone throughout the academic year which is equivalent to the production of 2.26 million plastic bottles. This project aims to design a novel smart mode of transport that will incentivise travellers to swap to a more sustainable option. The designed solution proposes an electric bicycle

shared system that adds new novel features specifically tailored to its users at Loughborough, as well as the inclusion of supporting systems such as parking, paying and security.

— “I will complete a Master’s Degree in Product Design Engineering, then to start my career as a design engineer in the renewable energy sector” —

GONZALO HERRANZ SARRION E: g.herranz11@gmail.com /gonzalo-herranz-sarrion

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SUPERVISORS: Melanie King & Pedro Ferreira

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PRODUCT DESIGN ENGINEERING PROJECTS

A sustainable product for domestic environments In developing countries, many people do not have access to infrastructure such as electricity or water pipes, so food is often wasted due to limited methods of food preservation while drinking water is often turbid. The aim of my project was to develop a low-cost, sustainable OBAN VAN SCHIE food preservation device. Through E: obanvanschie@gmail.com development, the design evolved into a system with dual functionality that would /oban-van-schiebe able to preserve food and produce 16b99117b/ clean potable water. To preserve food, my product uses evaporative cooling. ­— This is a method in which a layer of sand SUPERVISORS: and water is placed between two porous Dr James Colwill materials, in this case, a terracotta pot and an aluminium frame fitted with Dr Mey Goh terracotta tiles. As warm, dry air blows ­— against the outside of the terracotta, the water evaporates through the external tiles, causing heat transfer from the inner pot to the outside environment. The level of heat transfer is dependent on the external temperature so the product will be most effective in warmer climates, where the pot is able to reach refrigerator temperatures.

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A pipe system is fitted onto the base of the frame to allow excess water to filter through an activated charcoal filter into a clean water reservoir. The activated carbon absorbs impurities in the water as small as 2 microns. The product can be manufactured in a sustainable way and uses materials that can be locally sourced around the world with minimal environmental and ecological impact.

— “I plan on working in the product design industry after university and then doing a master’s degree in a few years.”

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PDE PROJECTS 2021

Improving 3D-printed ceramics via in-process inspection Additive manufacture (AM) is a relatively new form of manufacture and because of this, there are constant improvements being made to processes and the surrounding field of study.

There are several problems associated with AM, the focus of this study is porosity which effects the physical properties of parts, especially permittivity in electroceramics.

A non-destructive method for quantifying this porosity, is in-process inspection which, as the name suggests, is carried out while the part is manufactured removing the need for post-production porosity testing and verification.

This study proposes a method to predict total porosity of a given part, and the layer-by-layer porosity, with high levels of accuracy when verified with results obtained by taking physical measurements.

For the specific print parameters analysed, ‘layer height’ and ‘pulses’, it was found that predictions could be made within 4% and 5% of the measured values.

— “After my Master’s I hope to pursue a career in management” —

ALEXANDER SCOTT E: ascott.sco@gmail.com /alexander-scott27974b158

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SUPERVISOR : Daniel Engstrom

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PRODUCT DESIGN ENGINEERING PROJECTS

Design of an educational tool for sustainable development

ISABEL SEAKINS E: isabelseakins@outlook. com /isabelseakins

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SUPERVISORS: Shahin Rahimifard

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Living sustainably is one of the biggest challenges facing our generation, and educating the next generation is one of the best ways to tackle it. Consequently, this project focused on designing a learning tool that could be used within schools to educate children about sustainability.

The chosen subject was renewable energy, specifically wave energy. The product is an interactive water tank where kinetic energy from waves is converted into electrical energy, using an oscillating water column. The children can get involved by moving the board back and forth to create waves, and then watching the LEDs light up as electricity is produced. The conversion process involves the waves cyclically changing the pressure of a trapped volume of air within the column and forcing it to flow through fans which act as turbines. Depending on the size of waves, the voltage output will change, and a number of LEDs will light up. This introduces an element

of competition between children to see who can light up the most.

The aim of the tool is to get children engaged in the lesson and increase their awareness of sustainability issues. This will create a basis for future learning about how they can tackle some of the issues. The tool can also be used in other subjects in the National Curriculum, such as science, increasing its commercial appeal to teachers.

— “After completing my Masters degree in Product Design Engineering, I am aiming to begin a career in design and marketing of consumer products.”

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PDE PROJECTS 2021

Cleanliness assurance of reusable plastic packaging using ultraviolet fluorescence In the UK alone, margarine packaging represents more than 15,500 tonnes of polypropylene waste per year. Reuse systems combat single-use packaging by offering products in more durable packaging that is returned at the end of use, cleaned, and then refilled for the contents to be sold. However, growing concern over the possibility of foodborne illness from this type of system highlights the need for cleanliness checks between uses. Margarine contains fluorophores that fluoresce when exposed to ultraviolet light; this phenomenon could provide a way of checking cleaned reusable margarine containers for food residue.

This project investigates the design of a system that induces and detects margarine residue fluorescence on plastic packaging and the limitations associated with the system. The designed system consists of physical equipment, including a 344 – 412nm (ultraviolet) excitation light

source, and image processing software in MATLAB® using Otsu’s thresholding method. Testing was conducted so that the limitations could be explored and recommendation regarding system and packaging design could be made.

It was found that it is possible to identify food residue using the system; however, the margarine formulation, quantity of fouling, container geometry and material, and image processing technique all influence the extent to which margarine can be detected on the packaging.

— “I aim to finish my master’s degree in PDE at Loughborough before starting a career in a Research and Development role.”

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MALA SIAN E: m.r.sian-17@student. lboro.ac.uk /mala-sian

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SUPERVISOR: Elliot Woolley

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PRODUCT DESIGN ENGINEERING PROJECTS

Canal and river trust: promote wellbeing through technology

KATHERINE SLUMAN E: Katy.sluman@gmail.com /katy-sluman

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SUPERVISOR: Mey Goh

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With over 350,000 boaters on over 2500km of canals across the country, lack of data and information surrounding the waterways is becoming an increasing problem. With minimal internet and many users relying on paper maps, the relaxing seclusion of the waterways is part of the issue as users struggle to locate nearby amenities like shops, transport links, or hospitals in an emergency.

The aim of this project is to plan and develop a navigation app run by the Canal & River Trust (CRT) for use along the canals to assist canal users in journey navigation.

By creating an app in cooperation with CRT, users would receive high-quality, reliable information from one complete source, while being able to communicate data directly to the trust; alerting them to maintenance issues and allowing the CRT to monitor canal usage and receive realtime feedback from the very people they

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are providing for.

The problem was extensively studied to establish the main specification points of the app. This included route planning, offline capabilities and importantly a user friendly and well-designed interface.

Designs were drafted and a prototype was created including activity, wire flow and data flow diagrams to show the functionality of the product before establishing user feedback.

This process created a viable product that can be taken to an app developer for creation, to be run and monitored by the CRT to benefit both them and their users.

— “I hope to use my organisation skills to go into administration or project management. ” —

PDE PROJECTS 2021

Smart prosthetic design for lower limb prosthetic socket-parametric CAD modelling The socket on a lower limb prosthetic is the key contributor to an amputee using their prosthesis. The socket is the interface between standard mechanical components and the residual limb and thus must take the structure, anatomy, and biomechanics of the user into consideration.

Each prosthetic socket is bespoke to the user therefore the design and manufacture can be time consuming and labour intensive. This is particularly true in the traditional methods currently still used today. More modern techniques using computer aided (CAD) design and manufacture to design a CAD file, using a traditional software package and scan data of the residual limb, have shown greater results in regards to comfort and increased manoeuvrability in patients.

This method however, requires excellent CAD design skills and is time intensive, due to the complex natural form of the residual limb.

This project proposes a digital design methodology using a set of semiautomated digital parametric logic in a CAD package; the only inputs required are the residual limb scan data and key design factors such as socket thickness etc. A case study is carried out that tests the proposed methodology against 5 different and varying scan data. The results were positive, all 5 were able to provide and output file which, in all cases, was able to be converted to a Stereolithography (STL) file suggesting that manufacturing of the part is feasible.

— “I hope to go into a career in Engineering after travelling over the summer. Further developing the skills learnt through my degree and placement at Triumph motorcycles.”

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MATTHEW SMITH E: Matthewsmith337@ icloud.com /matthew-smith60281715b

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SUPERVISOR: Dr Simin Li

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PRODUCT DESIGN ENGINEERING PROJECTS

Orienteering anti-misting solution

WILLIAM SMITH E: Smith84willqwe@gmail. com /williamsmith-610097159

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SUPERVISOR: Mey Goh

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My project focused on designing a proofof-concept prototype product that greatly reduces the time taken for mist to clear on orienteer’s glasses. Currently, there are no products that provide a long-term viable solution for this problem and many orienteers are becoming deterred by the lack of safety and enjoyment that comes with impaired vision.

Several concepts were produced involving heating via convection and conduction, with a nichrome resistance wire selected to apply heat to the panes and make formation of condensation thermodynamically less favorable.

A circuit was designed using an Arduino that sensed local temperature and humidity and heated the wire, accordingly, using pulse width modulation technology and a MOSFET to vary current.

The final prototype featured a nichrome wire secured to the glasses with three clips that is powered intelligently using

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an Arduino, using a 9v battery. Both the battery and the processing circuit are situated in watertight housings on a headband with a visor hat keeps rain off the glasses and the electronics The prototype had the ability to greatly reduce the time taken for complete condensation coverage to dissipate and limited formation is regions in close proximity to the coil, proving the ultimate success of the project. All initial objectives and product design specifications were met with positive user feedback on the design and it’s usefulness within the sport.

— “I am hoping to graduate my masters next year here at Loughborough and then pursue a career in design consultancy.”

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PDE PROJECTS 2021

Additive manufacturing: pushing the boundaries with world leading software FullControl G-code designer is a new type of software for material extrusion 3D printing which avoids using CAD models and slicer software by instead allowing the user to explicitly define every stage of the printing process, providing unparalleled control over printing parameters, extrusion, nozzle pathing, and travel. This project explores using this software to design and print parametrically defined bioresorbable scaffolds and stents, for applications in the medical industry. Stents are devices commonly used to treat narrowed blood vessels caused by cardiovascular disease, the leading cause of death globally. Due to aging populations, the demand for improved stent systems is growing. FullControl could be used as an alternative process for producing stents, especially for bifurcated stents which cannot be made with the manufacturing techniques currently used in industry.

Work began with developing a method

of calibrating the printing parameters for a fused filament fabrication printer to generate freeform vertical, angled, and horizontal extrusions with a high level of consistency. The data collected from calibration was then implemented in designing and printing 3D structures, including tube scaffolds, bifurcated scaffolds, and stents lattices with more complex unit cell designs to provide improved flexibility and mechanical performance. A key benefit of using FullControl is being able to utilise parametric design to rapidly tailor G-code programs for each unique application.

DANNY SPRAGG E: spraggdaniel@gmail.com /spraggdaniel

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SUPERVISOR: Dr. Andy Gleadall

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— “I plan to continue broadening my knowledge and exploring the unique capabilities of additive manufacturing for problem solving in my further studies.”

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PRODUCT DESIGN ENGINEERING PROJECTS

Design and manufacture of a linear kicker using 3D-printing technologies

MIKE SYMINGTON E: mikesymington@yahoo. com /michael-symington678aa617a

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SUPERVISOR: Antony Sutton

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Kickers are designed and manufactured in the module WSD900 where they are programmed to strike a puck acting as a football at the desired force and direction towards the goal. The kicker is mounted to a stepper motor which allows it to decide on these parameters determined by an overhead camerasensor technology used to pick up the location of ‘defenders’ blocking the way whilst finding the best possible direction to strike the puck for it to land in the goal.

Shots towards goal can be taken from anywhere on the board as the kicker is able to move in both the ‘x’ and ‘y’ directions.

Metal-manufactured Pendulum Kickers are predominantly made for this purpose.

This project highlights the design and manufacture of a Kicker which fulfils the same purpose but instead with a linear motion. The design of the Linear Kicker is to be done with the use of 3D-printing technologies instead, encouraging the

flexibility of incorporating intricate shapes into the design.

The ultimate goal for this project is to not just design a kicker which is able to fulfil the purpose of scoring a goal, but to do it well and at a high standard. From the start of the project, the ideal kicker I envisioned on making is a lightweight cost-effective prototype with a simple yet impactful design avoiding the potential of over-engineering the concept with the three main priorities of the kicker’s performance being Consistency, Efficiency and Repeatability.

— “In the near future, I plan on gaining industry experience through placements to figure out which area I find the most enjoyable to work in Design Engineering ” —

PDE PROJECTS 2021

Design of a product to reduce insomnia and improve sleep quality Sleep at times is taken for granted and people forget the important role it plays in everyone’s daily routine. Sufferers of the sleep disorder, Obstructive Sleep Apnoea (OSA) are often neglected unknowingly by the individuals themselves or those around them due to the lack of knowledge of the condition. Miscommunications to health professionals like GP could therefore extend their wait before actual diagnosis and would therefore lead to unwanted daily life struggles.

Those fortunate to have been diagnosed may lose the drive to maintain their treatment which leads to unwanted setbacks. Both problems could lead OSA patients to experience severe physical health issues, mental and emotional issues, and social issues. These address a need to create an occupational tool to improve future and current OSA patients’ experiences.

The scope of the project is to design a product that educates those potentially with OSA to reduce their pre-diagnosis time and provide an occupational care service to show diagnosed OSA patients their recovery journey to promote the drive for a full recovery and change in lifestyle. The final proposal is an ankle based wearable product linked with a mobile interface. The product system combines measured metric and emotive results giving users updates about their sleep and OSA recovery progression.

NATALIE TANG E: wkntang99@gmail.com

— “After graduation, I aim to complete a master’s degree in Innovation, Entrepreneurship and Management with hopes in the future to help small medium enterprises to grow and uncover their true potentials.”

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/wkntang-1999

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SUPERVISOR: Paul Maynard

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PRODUCT DESIGN ENGINEERING PROJECTS

Design of a hearing aid calibration device The likelihood of developing hearing loss increases dramatically with old age, with 71% of people over the age of 70 suffering, and with care homes disproportionately impacted.

DAVID TAYLOR E: Djft2013@gmail.com /david-taylor-335724142

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SUPERVISOR: James Colwill

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While hearing aids are used to mitigate the problems of hearing loss, NHS hearing aids give poor feedback, and a lack of carer training leaves residents with hearing aids which have flat batteries or are accidently switched off.

The aim of the project was to design a low-cost handheld device that could quickly test a hearing aid by checking that it is on and functional.

Magnetic induction was identified as a viable way of transmitting a test signal to a hearing aid, which would only be heard if the aid was on and had battery.

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The final design, the checkaid, is a battery powered pocket-sized device that produces a test signal for a hearing aid to receive. After the hearing aid has been set to Telecoil mode, a carer holds the checkaid up to transmit the signal; if the signal heard, the aid is working, if not the aids batteries should be changed.

2 audio sources, an astable 555 timer and a Bluetooth module connected to a phone app, allow a fix 2kHz tone or pre-recorded messages to be used as a test signal.

— “I hope to work on innovative consumer product projects that solve problems people face daily.”

—

PDE PROJECTS 2021

Re-purposing WEEE for a low-cost lighting system The management of e-waste is a growing issue, with most e-waste being incorrectly disposed of. Much of the waste collected for recycling is illegally exported to vulnerable places like Agbogbloshie, Ghana, which is the world’s largest e-waste dumpsite. Many locals in Agbogbloshie work as informal e-waste recyclers and live in urban slums surrounding the dumpsite. Here, they have no access to electricity and rely on kerosene for lighting which is expensive and detrimental to their health. Current low-cost lighting solutions do not utilise the abundance of WEEE to manufacture it, therefore there is a clear gap in the market to produce a low-cost lighting system made from WEEE. This project proposes a lighting system design made from WEEE which provides indoor lighting for 6 houses for at least 4 hours of electrified lighting per day.

The system also includes one shared outdoor light to improve perceived safety of the area.

To generate energy, an 80W reclaimed solar panel is used in conjunction with a Savonius wind turbine made from repurposed white goods, and a stepper motor as the generator.

Four different generators were tested (three brushed DC motors from WEEE and one new stepper motor) and a prototype wind turbine was made.

Laboratory and wind tunnel testing was conducted to establish its viability and results showed that the stepper motor was able to generate adequate power at speeds of 1186RPM.

— “After graduation I hope to pursue a career in sustainability. I aim to work as a consultant for organisations looking to become more green.”

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KIARA TAYLOR E: kiara.taylor@gmail.com /kiara-taylor-0309

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SUPERVISOR: James Colwill

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PRODUCT DESIGN ENGINEERING PROJECTS

The design of a smart hobby tool

DANIEL TIMMERMAN E: dantimmerman18415@ gmail.com /danieltimmer manengineering

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SUPERVISOR: Dr Lewis Jones

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Sustainability is an important aspect of every design but can be overlooked due to complex tools with high barriers for entry.

This project used simple tools, such as a design language, eco-BOM (a bill of materials including an estimate of the energy to produce an item) and an environmental design failure mode effect analysis (which adds the environmental impact of a failure occurring along and the difficulty to repair alongside regular severity and probability), to tackle this.

In the end, a hand-held drill was designed using these tools with repairability and sustainability at its heart – showing that designing sustainably is no more difficult and takes no more time than the regular design process.

— “Firstly, onto MEng and then we shall see!”

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PDE PROJECTS 2021

Development of a phantom head model for the experimental validation of a new technique for the imaging of human head tissues.

Electric Impedance Tomography (EIT) is a new imaging technique which uses low frequency, alternating currents to map the impedances of body tissues. It provides a safe, non-invasive method of imaging patients which can be beneficial for clinical applications, such as stroke detection. To validate new imaging technologies, phantom models are commonly used and these must be geometrically and dielectrically accurate to provide a suitable representation of the human anatomy.

This project aimed to develop a multilayered head phantom, containing both the soft and hard tissues, to test alongside a novel EIT system and to develop recipes for phantom materials which accurately mimic the dielectric behavior of these tissues within the frequency range of 100Hz to 1MHz. To create a geometrically accurate soft tissue phantom, CAD files from previously

extracted DICOM images were used to construct 3D printed models that were used to make high resolution silicone moulds. For the hard tissue layers, 3D printed TPU moulds were used. The established manufacturing process was tested and verified, resulting in the production of a coloured, multi-layered phantom.

To create the phantom materials required, various agar-gelatine based recipes were tested and doped with additives, such as NaCl, propylene glycol, PVC and nylon, to adjust their dielectric behaviour. The recipes were then tested at the set frequency using an impedance analyser.

LASATA TULADHAR E: lasatatuladhar@outlook.com /linkedin

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SUPERVISOR: Kaddour Bouazza-Marouf

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— “After completing a Masters in Product Design Engineering at Loughborough, I hope to pursue a career in medical engineering and design.”

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PRODUCT DESIGN ENGINEERING PROJECTS

Development of a sensory product for people with autism

KATIE WARRINGTON kdwarrington17. myportfolio.com E: Kdwarrington16@gmail. com /linkedin

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SUPERVISOR: Dr Rebecca Grant

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Sensory overload can be experienced over four times per day by people with Autism Spectrum Disorder (ASD) and is characterised by a difficulty to process their surroundings. 1 in 100 people in the UK are on the Autism spectrum: a neurodevelopmental disorder presenting most commonly as impaired communication and restricted interests. Current solutions to manage sensory overload are unreliable and rigid, therefore a clear gap in the market was identified.

Research into emotional design and ergonomics identified key methodologies to apply to the design of a new unobtrusive chair-hideaway, designed specifically to reduce the severity and frequency of sensory overload in young autistic females aged between 7-11 years.

Key product features include blocking stimulus, comforting textures and deep pressure. Further work is required to quantify whether the proposed solution proves effective during overload for individuals with autism, however other specifications were achieved.

— “After completing a summer placement with Renishaw in their Industrial Design and Human Factors team, I will be concluding my MEng at Loughborough University.

Following this, I will be pursuing a career in ergonomics and design. ” —

PDE PROJECTS 2021

SMART designs: a circular economy for sports and exercise equipment The forced closures of gyms and an increase in leisure time due to the coronavirus pandemic, as well as growing awareness of the importance of health and well-being, has resulted in exponential growth.

Due to the unforeseen nature of the pandemic, the growth of investment into research and development has not occurred on the same scale as sales.

This has created the perfect storm for an environmental crisis within the sports and exercise equipment industry.

Little material innovation, complex disassembly and expensive recycling has resulted in the treadmill being environmentally damaging.

Three different concepts were taken forward to development: 1. Self-lubrication. A self-lubrication device uses the energy dissipated through the treadmill deck by the user to pump lubricant onto the treadmill deck, ensuring accurate and consistent deck lubrication and preventing the motor from excessive strain.

2. Design for disassembly. By utilising snapto-fit joints, disassembly is quicker and uses less material types, making recycling easier. Using a given force the dimensions of the cantilever snap joints were calculated, but the method is reproducible and can be applied to any component beyond the scope of sports and exercise equipment.

CHRISTIAN WHARTON-HOWETT E: christianhowett@icloud.com /christian-wharton-howett

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SUPERVISOR: Shahin Rahimifard

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3. Product for life. The use of a replaceable motor and motor control board prevent premature end-of-life and allow the user to upgrade the specification of their treadmill.

— “Following graduation, I will pursue a career in design engineering. Until then I will continue my development within the engineering field through different projects where possible.”

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PRODUCT DESIGN ENGINEERING PROJECTS

Understanding how hot lithography can reduce the peeling forces when using vat polymerisation 3D printing Currently there is very little information or research surrounding hotlithography.

This study aims to break down the key factors which are affected by changes to the printing temperature during vat-polymerisation and understand KIERAN which temperature is the optimum to WHITEHALL print at, to ensure that the peeling forces E: Krwhitehall@hotmail.com are minimal. This study involves printing and testing two separate mixtures with /kieran-whitehalldifferent binder formulation and different 92aaa717a mechanical properties.

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SUPERVISOR: Ehsan Sabet

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A variety of tests were carried out on the resins and unsintered bars to understand how the printing temperature was affecting the properties of the material during the printing cycle. These tests included tensile tests, 3-point bending tests and a force test. To maintain fair tests, the test samples were produced to the same dimensions and were not allow for post cure after printing before the tests had been completed. Through the research it was found that trends did form. It was found that the viscosity of the

ceramic slurry was a key factor in the peeling forces experienced between the vat and the part layers.

Due to curing at higher temperatures, it was found that some outcomes contradicted each other, where the slurry was thought to be less viscos but through the results it was evident this could not be the case. The optimum conditions found to be used were, the B37 resin at a printing temperature of 35°C, where it has a peeling force of 3N and a flexural strength of 42MPa.

— “After gaining invaluable skills from my placement next year and completing my master’s degree in Product Design Engineering I would like to pursue a career within the manufacturing engineering industry.”

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PDE PROJECTS 2021

Design of an electro-mechanical musical device that, working with a touchscreen device, replaces traditional midi music peripherals Since the creation of the modern piano in 1700, the musical keyboard has steadily advanced with technology. Today, tablets are becoming common in consumer and professional computing. While only the start, there is a market gap for a new generation of music keyboard that caters for this generation of computing.

was imperative to prevent coverage of non-keyboard UI touchscreen elements.

This resulted in a sliding case that rests only on the bezels and keyboard UI.

This project presents the design and development of a physical music keyboard that integrates with a touchscreen tablet.

This combination resulted in a functional, touchscreen-enabled, prototype that provides key feel similar to existing keyboards. It successfully proves feasibility of an alternative keyboard designed for this generation of computing, as it fulfils customer needs, is mechanical and can be manufactured and assembled at prototype level.

Winning designs from a range of initial concepts were developed and iterated in four key areas.

The first area is touchscreen interaction.

This resulted in a key that directly translates a press into capacitive touch.

Second is actuation. This resulted in a functional mechanism enclosed within a chassis for key expression. Third is casing. Product sizing and portability were challenging design constraints as it

Finally, software was developed to test for key strikes and to demonstrate the capability of aftertouch on the iPad.

WILLIAM WHITELEY E: liamwhiteley@icloud.com /williamwhiteley

­— SUPERVISOR: Ian Graham

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— “I am looking forward to a career, or start-up, in designing and developing exciting new products in response to a rapidly evolving technology landscape.”

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PRODUCT DESIGN ENGINEERING PROJECTS

Developing and designing a data acquisition box for biomechanical sensory data

MAX WORKMAN maxworkman.wixsite.com/ mysite E: maxworkman@hotmail. com /maxworkman

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SUPERVISOR: Ella Mae Hubbard

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This project was completed as part of a larger DigiTOP project which aims to develop a toolkit to optimise productivity and communication between human workers and robots.

A prototype was developed under the DigiTOP project using a Raspberry Pi, housed in an acquisition box, designed to be worn by a human. This acquisition box controls the interactions between the human and the robot by monitoring the human movement through wearable sensors.

However, following testing, it was necessary to upgrade the technology to include a printed circuit board that would work with the Raspberry Pi, meaning that the acquisition box had to be redesigned.

The redesign of this acquisition box and the associated hardware was the main focus of this project. The main challenge was to determine how the acquisition box can be modelled to be aesthetic, ergonomic and comfortable to enhance the user‘s experience and improve operating outcomes.

— “I plan to pursue a career in Product Design, hopefully setting up my own business in the near future using my knowledge, skills and experience. ” —

NOTES:

NOTES:

Wolfson Building Loughborough University Leicestershire LE11 3TU UK

www.lboro.ac.uk/meme Brochure Academic Lead: Dr Ian J Graham Cover Concept: Shreeya Patel

@Lboroeng /Lboroeng /Lboroengineering

79398/CPS/JUN21

PDE Projects 2021