Product Design Engineer
Peter Davies
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Heritage Freelance
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Carpet Cleaner Range Refresh
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PRODUCT
Vax’s bestselling and best performing carpet washer to date, the Platinum Power Max Carpet Cleaner cleans your carpets 5 times better than a high-performance vacuum cleaner. Many complex subsystems and technologies such as Automix, Dual V and Spinscrubs come together to provide a level of clean proven to beat even the markets leading rentals. After many successful years in the market already, it was necessary to refresh the platform and to further bolster the proposal with new Antimicrobial action.
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PROGRAMME Although the Platinum project singularly held great importance for the business, it was also part of the wider 2019 Carpet Washing range that I was responsible for, which collectively made a significant part of Vax’s strategy for 2019.
With Platinum as the flagship product, the range also required several new exciting SKU launches as wel as other product refreshes, all requiring to be worked through in parallel with similar timelines.
For example, the Compact Power Carpet cleaner required a significant amount of design work to make it compliant and viable for EMEA markets, having previously been released initially in North America only.
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As well as conventional design work, there were also extensive R+D research objectives that were necessary so that new bolder marketing claims could be made and validated for the existing platforms.
PRODUCTION
A major part of each of the projects were the regular extended trips to the OEMs in China, for review and supervision of the injection samples, assembly lines, quality testing as well as other tertiary suppliers i.e. printers.
Often working independently, it would be my responsibility to make approvals and quick decisions on site regarding the projects, as well as co-ordinating communication and feedback between UK, US and Chinese offices.
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Chemical Free Contact Lens Cleaning and Disinfection
Final year project Loughborough University
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PROBLEM 6 MILLION
ÂŁ79
MILLION
UK contact lens wearers, the spent on lens cleaning solumajority aged between 16-44 tions this year in the UK alone
Current contact lens cleaning practices advised by optometrists are entirely manual, relying on fine motor movements, visual acuity and purchased disinfecting chemicals. Primary research has found that many contact lens wearers find lens care to be a messy, fiddly, laborious and expensive process. Personal aversions to care routines result in reduced compliance, threatening the health of the wearer. Conversely, repetitive exposure to cleaning solutions can induce sensitivity and dry eyes.
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PROCESS
Iteration through cardboard prototyping drove concept development, allowing a co-design method to incorporate champion users directly into the process
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Contact lens marketing focuses on clean, calming, natural themes, particularly aquatic. This is reflected in the choice of technologies, colour pallet and surfacing.
Interoperability between NURBS and Mesh CAD packages allowed for the sophisticated geometric surface detailing
The components were optimised for fabrication in each of the chosen methods, e.g. the shell was segmented subtly into flat planes for efficient additive manufacture
Expertise was exercised in metal fabrication, plastic forming and finishing, creating jigs and formers to assist fabrication
Smart embedded system utilised realistic commercial electrical components
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PROPOSAL
Moist air is discretely drawn in from the environment through HEPA filters, to be condensed into water on antimicrobial copper heat sinks via a thermo-electric cooler.
Using FDA approved technology, a whirlpool loosens debris whilst germicidal UVC radiation destroys pathogens within 15 minutes - resulting in significantly cleaner + clearer lenses.
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Embedded system monitors water tank capacity for efficient energy use, as a result the cost of running the device is 97.6% cheaper than purchasing cleaning solutions for a year. The water tank is also removable and made from dish washer safe materials for easy cleaning.
Lens case has been ergonomically designed with proven positive benefits of quicker, safer, more hygienic interactions.
Case lid resits on top of case for a larger object to hold and control, without contaminating any surface that would affect the lens.
Adapted lens holder allows easy access to the lens from underneath rather than scooping, bypassing the need for handling and orientating the lens.
The lens therefore remains in the correct orientation and the chances of contaminating the lens holder through touching is reduced.
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Final year optional module CAD/CAM Loughborough University
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PROSPECT
The power drill is a fundamental tool but vital to a tradesman’s daily activities and their ability to earn a living. With daily use in a laborious trade, a quality product with a comfortable grip is crucial. ‘Relief’ marks a new breed of power tool, utilising Additive Manufacture to provide a bespoke product that befits the important role that tools possess in a tradesman’s life. The flagship feature of the range is the personalised grip, tailor made to the contours of the individual’s hand, using anthropometric data from captured 3D scan data.
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PROCEDURE 3D Systems Sense scanner and Z Corp Laser scanner were both used to compare the different possible resolutions.
The mesh scan data was first imported into Rhinoceros for clean-up, hole patching, anomaly removal and orientating.
The refined scan data was then imported into Creo Parametric for surface modelling, which was a compromise of accuracy and surface quality.
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Using reference images, the scan data was integrated into the existing drill body design, ensuring consistent proportions and geometric accuracy.
A mixture of surface and solid modelling techniques were employed to create the complete drill body, ensuring sophisticated surface transitions where maintained up to and including G2.
The generic shell design was optimised for additive manufacture, including more natural split lines, personal customisation and reduction of parts.
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Placement Year Replica ornate truss system for traditional timber greenhouses
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Heritage
PLACEMENT
As a bespoke joinery firm, Woodpecker Joinery is frequently contracted to replace antique timber greenhouses on sites of historical significance or outstanding natural beauty. The Victorian greenhouses that fall into disrepair are often outfitted with cast iron metal works that are integral to the design of the structure. While it is sometimes possible to repurpose the existing iron work, it has become apparent that Woodpecker requires its own replica metal work to offer clients as a part of their capabilities.
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PROGRESSION Initial designs were for a unique surface modelled decorative motif that would be consistent across internal supports and external cresting.
Extensive historical research informed further designs that paid homage to the history of horticultural buildings, closely following the trends of the traditional Victorian style.
Iterative cardboard prototypes were used to evaluate the scale and proportions of the design against the timber sections and to obtain feedback from clients.
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Iterative CAD models were produced based upon consultations with clients, managers and manufacturers to ensure a desirable, cost effective and feasible outcome.
A holistic CAD virtual environment was built up to investigate the mechanical characteristics of the design in situ, resulting in instances of geometric optimisation.
The design was batch manufactured, using modern alloys for improved performance whilst also paying homage to the past through traditional sand casting methods.
The final design was unveiled at the Chelsea Flower show before the public discerning clients and celebrities. The bracket designs were complimented by a fully functional, manually operated, geared bell crank ventilation system.
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Freelance 22
PROMOTION
Outside of office hours, I undertake freelance graphic design projects on behalf of several premiership American Football Club’s as well as the Great Britain men’s national team. Content has included: Logo and branding support, Photo manipulation, poster and flyer production, match day programmes, Video capture and edit-ing, event banners, social media content for a variety of platforms as well as web support.
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PRINTING Training shirt designs commissioned by the Great Britain Men’s American Football team for their training camps ahead of the World Championships.
Merchandise commissioned by Phil3 Productions, independent photographer. Artwork and work wear produced based on existing brand.
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Training tops commissioned by Loughborough Students American Football Club, in order to create a visible public presence and unit identity outside of organised workouts.
Promotional video commissioned by LSAFC for the 2017 recruitment drive, combining studio, in environment and live action footage
Web, social media and printed content produced to support LSAFC throughout the 2017. A unique brand was established for 2017 and consistently executed across all publications.
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