1
2
3
1
REPERIO
A build-it-yourself alarm clock 5 - 14
2 SIXSENS A motorcycle awareness device 15 - 18 3 SLITË
Upcycled, handmade coasters 19 - 22
4
CAN CRUSHER
5
VAHVIS
6
ECLIPSE 1930’s stylised DAB radio 35 - 38
7
CONNECT Injection moulded children’s mouse 39 - 44
8
ADDITIONAL PROJECTS
Team mechanics project 23 - 28
A customisable guitar amplifier
29 - 34
Various other works 45 - 46
4
5
A BUILD-IT-YOURSELF ALARM CLOCK DESIGNED TO TEACH REPAIR
6
PROJECT 24 weeks
BRIEF
To design a household product, or suite of household products that teach transferrable assembly and disassembly skills to users, along with basic electronics. The design/s should encourage repair and create a better user-product relationship with the products they use on a regular basis.
Discover Learn Obtain Invent SA
LE
TIMESCALE
7
We are not taught how to repair things any more. Where before there was home economics, there is no room in the curriculum for the like.
The rise of inexpensive, accessible products is partly to blame for the Throwaway Society we live in today. Replacing is cheaper than repairing.
840000 tonnes of WEEE were discarded and uncollected in the UK in 2012. The amount is much bigger worldwide, and the number is only growing.
A study on attitudes to product obsolescence suggests that appliances only last two thirds as long as consumers deem reasonable.
77% of people surveyed would not feel comfortable repairing their own products. Half have never tried. There is a taboo around attempting.
There is already a strong community of people that focus on trying to repair or make their own items. They need more support.
PURPOSE Reperio is targeted at unconscious consumers who naturally throw their products to landfill than repair. There seems to be a taboo concering repair; people think it is scarier than it should be. Reperio aims to increase confidence and educate users about their household products in a holistic manner to encourage a change in behaviour. The product has been designed to teach transferrable skills userscan apply to other products if they are damaged, or at least try.
FUTURE The hope is that Reperio would be an honest, passionate brand that could introduce a whole range of electronic household products based around these aspirations. The application of this project could be undertaken for any other product. A hairdryer, a kettle, a television. The more products created, the more people know about them, and the more people begin to realise they don’t need the latest thing, they need the right thing.
8
DEVELOPMENT WORK
A multitude of concepts were generated, exhausting a number of different directions for the product. Once a path was chosen following user feedback and decision matrices, sketched development was relied on heavily. It allowed for rapid solutions without constraint. The more promising additions could be tested and experimented using card or foam models, and finally be input into the CAD file.
9
Fabrication process A meticulous prototyping plan was created and discussed with technicians. Once ďŹ nalised, a GANTT chart was developed to enable to steady and organised fabrication process. Throughout the project the plans were used to time-keep and analyse the current situation, allowing for any contingency plans to be introduced following any set-backs. A variety of skills were learnt from start to ďŹ nish, and the manufacturing was a delight.
Foam models; Card models; Rapid prototyping; Milling; lathing; laser cutting; line bending; CNC machining; Sanding; Painting; Priming; Soldering; Electronic PCB design; Electronics testing; Tapping
10
INSTRUCTIONS A concise set of instructons were designed and bound into a booklet. They began with information about each electronic component followed by how to wire them using colour-coded and numbered wires. Leading into the assembly, sub-sections were created which defined a small number of parts needed, and universally comprehensable instructions on how to construct them. An intuitive method of wiring the elecronic components to the Raspberry Pi was defined. After the assembly, if the user desires to disassemble Reperio, they are advised to simply follow the instructions backwards. They are also given information on the disassembly and disposal of the product, grouping each component into their respective materials, and informing how to discard of them responsibly.
INTERFACE Reperio is a multifunctional device. It is a clock and alarm clock, a speaker, and a dimmable lamp. The interface went through iterations that were assessed by users. The chosen interface was developed and designed, finally being prototyped on Axure. Tests were conducted and any feedback was analysed and used to tweak the final version of the interface.
USER TESTING User testing was utilised throughout the project. It was used to not only help design the product, but help evaluate the finished item. I gathered 5 target users and presented the product in its flat-pack state. Users were told to follow instructions and assemble the whole real product, including the wiring. Tests were a success overall, and valuable information was learnt that could be taken forward to the Design for Manufacture.
11
SCENARIO
One
The product is presented to the user in �lat-pack form
Two Follow the instructions to construct the product
Three This includes screwing in every component
Four The electronics are also wired from scratch
Five
Once it’s finished, Reperio is a fully-functioning product!
12
Simple function buttons Universal power source
Rotate the head display 90 degrees to increase longevity Colour-coded removable components
Simplified repair
Modern sustainable materials Dimmable lamp
Sunrise alarm
DESIGN FOR MANUFACTURE DEVELOPMENT Where the original CAD was empathetic of prototyping, the manufacturing method for each component was defined, allowing for tweaks and optimisation to bring the product as close to professional manufacture as possible.
65,000 UNITS
13
£60 RRP
VOLUME The potential real market was critically analysed enforcing an estimated global production value. Trends and market sector statistics were evaluated, along with the predicted audience.
COST Taking material cost, manufacturing method, volume, and other factors into account, a production cost of £20 was generated which informed the retail price.
MATERIALS
ASSEMBLY
ELECTRONICS
REPAIR
DISASSEMBLY
DISPOSAL
14
SIXSENS
An extra eye for truck drivers
15
A brief set by
16
PROJECT TIMESCALE
10 days
BRIEF
To use existing or potential sensory technology and apply this to a product in order to solve a problem in the workplace.
INSIGHTS
difficult to see on the motorway because of their size, and also hard to hear,
Motorcyclists can be incredibly
PROBLEM
Drivers of heavy goods vehicles often struggle to notice motorcyclists whilst driving due to large blind spots on either side of the truck, resulting in fatalities.
meaning double and triple checking as a necessity. This makes it harder to concentrate on other areas I need to.
Cars are usually easier to spot. They are more predictable than motorcyles. The amount of times I’ve had a close encounter with a biker that has tried to over-
or undertake me at fast
speeds is crazy.
BLIND SPOTS There was a noticeable similarity with answers from interviewees when asked about their blind spots and the main dangers they encounter. Drivers’ attention is often compromised because of the need to focus on blind spots to the best they can.
17
OPPORTUNITIES
TECHNOLOGY
A device that can be programmed to listen for engine frequencies of motorcycles, and wirelessly link up to a partner device in the cabin in order to audibly notify the driver of a motorcycle in the vicinity. This would make him/her instantly more aware, and offers an extra sense to assist the blind eye. Whilst still unable to see them, they know of their whereabouts.
Noise cancelling technology eliminates unwanted frequencies by internally creating the opposite frequency to the input which in effect creates silence. This could be applied to engines because every engine type has a unique sound, meaning it is possible to concentrate on listening for specific ones.
SCENARIO
2
1
3
Turn external device on
5
4
Attach to vehicle
Motorcycle approaches
Turn on partner device and attach to dash
Device hears the engine and sends signal
6
Partner device sounds a ‘beep’
The benefit of sendng a sound signal is to surprise the driver and switch their brain on by triggering another sense.
18
19
20
21
22
23
24
PROJECT SPECIFICATION MECHANICS
TIMESCALE
Individual Group
BRIEF
Firstly, to individually design an electromechanical can crusher able to crush both 330ml and 440ml cans, completing a full mechanical analysis and product design specification. Secondly, to get into groups of three and select the most appropriate design to take forward for manufacture, then do so ready for a competition.
6 weeks 6 weeks
The device: Must be powered by a 12V DC motor. Must be capable of storing 5 of both 330ml and 440ml cans with the ability to automatically load and eject itself without human intervention. Must be capable of crushing a both size cans to 20% of their original volume.
ELECTRONICS
The device: Must be operated using a PIC18F45K20 microcontroller. Must display the crushing time and force at a minimum. Must be operated via push buttons and must automatically cease crushing when all five stored cans have been crushed. Must incorporate a kill switch/emergency stop.
Thorough mechanical analysis was completed for each component that was subject to a load. The main driving shaft for my design was a crank and slider mechanism. Other calculations included gear trains, factor of safety, axial loading, shear stress, bending moments, and tear out.
My individual design was cenetered around a crank and slider mechanism which assisted in loading the cans from the hopper on the back-stroke. Small spurr gears were used at a ratio of 5:1 to generate enough power to crush the can to the required depth. These would then be ejected through a hole in the bottom of the shaft once small enough.
Crank arm 72.5mm
Slider arm 220mm 175° Fout
T=5.5Nm Motion
THE CHOSEN ONE The chosen design was collectively developed using Creo in order to prepare it for fabrication. Any changes were accounted for with further mechanical calculations.
25
GROUP WORK The work was delegated amongst the team members according to their specific strengths. This allowed for a more efficient and strong unit. FABRICATION The crusher was purposely designed so that the majority of components could be cut on the waterjet cutter. This increased accuracy and removed the human error. STANDARD PARTS Gears and bearings were purchased externally. The expense was necessary to save time and ensure professional accuracy. It was important that the crusher ran at the highest efficiency.
26
TESTING
When the code was created, each of the functionalities were tested on breadboard to ensure everything was working correctly before committing to PCB.
WIRING
Once we were confident with the coding, a PCB was designed and fabricated, and each component was added incrementally. This allowed us to thoroughly test and fix any bugs or problems straight away.
INTEGRATION
The final stage was to mount the electronics onto the can crusher. Since this had already been taken into account during design development it was made much easier. Colour-coded jumper cables were used to organise the components and provide a temporary fix in case of any mistakes.
27
28
30
31
32
33
34
35
A classic twist on modern radio
PROJECT TIMESCALE
6 weeks
BRIEF
To gather inspirtaion from the 1930’s idea of streamlined products and apply techniques learned in order to design a modern DAB radio. Standardised electronic components were provided at the beginning and it was imperitive that the radio could house them.
37
Vintage interface style
VOL
13:06 MAGIC
HEART
CHOICE
SMOOTH
KISS
CLASSIC FM
TALK SPORT
JAZZ FM
PLANET ROCK
RADIO X
CAPITAL FM
KERRANG
ABSOLUTE
BBC RADIO 2
BBC RADIO 1
BBC RADIO 4
BBC RADIO 3
BBC RADIO 6
BBC RADIO 5
JAZZ FM
Modern interpretation on 30’s streamline
38
39
Connect An injection-moulded children’s mouse
40
PROJECT TIMESCALE
Design Fabrication
BRIEF
To design a computer mouse intended for a children’s magazine giveaway and then design and fabricate a fully-functional injection-mould tool. The design of the tool was completely independant, then after completion, a group of ďŹ ve was collated and the most feasible design was taken to manufacture. Mine was the chosen design.
6 weeks 6 weeks
BUILD DIGITALLY
INITIAL DEVELOPMENT
Mould tool development was primarily completed via sketching. It was imperitive that this was done hand-in-hand with CAD, since it was easier to spot errors and create an overtly detailed design before the wrong direction was taken.
41
The prototyping was delegated equally between all ďŹ ve team members. Where possible, the inserts were fabricated manually. A minimal amount were CNC-routed, including the logo engraving. Each part was manufactured to a tolerance of 0.1mm to ensure no leakage during injection. The toleranced ďŹ nish was achieved using a grinder. The plastic injection was successful.
42
The logo was inverted and machined using the engraving CNC tool.
The studs were designed to be compatible with real LEGO pieces.
MASS MANUFACTURE Since this was designed to be a giveaway widget, considering the cost is vital to understanding whether this could be a feasible project. It was calculated using CAD flow systems that 4 widgets could be injected every 9.2 seconds. This means 250,434 per week, and 3,005,216 in the targeted three months. Taking into account the price per kilo of Polypropylene, it was established that the material cost of one widget was two pence. The total cost for three million would be £60,104.
43
The sprue was located at the most efficient possible point in the mould.
Dovetail joints connect the two halves, allowing for colour combination.
44
ADDITIONAL ADDITIONAL PROJECTS PROJECTS ADDITIONAL PROJECTS ADDITIONAL PROJECTS Consisting of passion projects, commissions, and placement work, these additions represent a range of abilities, versatilities and interests of mine. Feel free to ask me any questions you may have!
45
Dad’s Birthday Present Passion project
Pizza oven Placement
Tart Packaging Passion project
TV Stand Commission
Hive Passion project
Retirement gift Commission
Tilly’s Treats Branding Placement
X-Trail Uni project
Hot Smoky Bastard Brand Placement
Deer Passion project