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HAND MADE - HIGH TECH 1 American Football Helmet

Concept 2 Trainers

Rowing Oars

First created in 1915 – which were made out of leather. During the World War I harder leather were used to make helmets. Not long after fabric cushions were added to soften the collision of players.When John Tate Riddell’s company started creating helmets in 1939 made out of plastic, this led to redesigning the whole helmet. Adding straps to be fixed around the chin instead of the neck. Holes for ventilation or airflow for hygiene purposes and on field communication.

Basketball trainers by APL is designed to give players boost on their vertical jump. The Load ‘N Launch™ Technology makes all this possible. The Goldston brothers basketball fans, college graduate and loves jumping higher. The brothers designed the basketball trainer like a diving board. When you walk on it, its like normal surface but when you put a downward force/pressure on to it, the board propels you up. Its an instant advantage. Using less energy to jump higher. Basically improve performance..

In rowing, are used to propel the boat. Oars differ from paddles in that they use a fixed fulcrum to transfer power from the handle to the blade, rather than using the athlete’s shoulders or hands as the pivot-point as in canoeing and kayaking.

What is it made out of? (current NFL helmets) + Made out of Poly-carbonate plastic (Plastic pellets) + padding (vinyl and foam) + face guard (plastic coated steel) + chin strap (polyester)


1 poly-carbonate pellets are melted and moulded 2 Robot/machine transfers it to a conveyor 3 Human clips off excess plastic 4 Robot/machine drills holes for precission 5 Human collects helmet for sanding, priming, painting 6 Skewered and leave to dry to harden paint. Giving extra durability 7 Adding the foam to the helmet 8 Impact testing 9 Finish by adding the face guard and chin straps

What is Poly-carbonate plastic?

A type of a thermo-plastic polymer that is used for commodity and engineering plastic.

Why Poly-carbonate plastic?

Because of their strength and weight and their properties to be easily formed and thermoformed. Its feature includes temperature resistance, impact resistance and optical properties. Main transformation techniques for polycarbonate resins: + extrusion into tubes, rods and other profiles including multiwall + extrusion with cylinders (calanders) into sheets (0.5–20 mm (0.020–0.79 in)) and films (below 1 mm (0.039 in)), which can be used directly or manufactured into other shapes using thermoforming or secondary fabrication techniques, such as bending, drilling, routing, laser cutting etc.

The Design

The Launch Pad is where the Load and Launch is located. And it is by the forefoot where we put more pressure/force when jumping. High-density collar padding on the interior is designed to maximize comfort comfort and return of energy during jumps. The new herringbone outsole features a high grip tread pattern designed to optimize traction, maximize surface contact area and the user gain the full benefit of the APL Load’ N Launch technology. Maximize comfort comfort and return of energy during jumps. The new herringbone outsole features a high grip tread pattern designed to optimize traction, maximize surface contact area and the user gain the full benefit of the APL Load’ N Launch technology. The aerodynamics of the shoe creates an optimal drag coefficient and helps position the foot to be able to realize the full benefit of the patent-pending Load ‘N Launch technology. The two-piece synthetic carbon fiber upper molds to your foot using minimal seams and stitch lines to provide superior comfort and a high-performance fit. Integrated flow vents placed in strategic locations combine with an open air mesh tongue to allow cool air to come in and heat to flow out.


+ Thermoplastic polyurethane is any of a class of polyurethane plastics with many useful properties, including elasticity, transparency, and resistance to oil, grease and abrasion. Technically, they are thermoplastic elastomers consisting of linear segmented block copolymers composed of hard and soft segments. (Thermoplastic Polyurethane) + Springs is an elastic object used to store mechanical energy. Springs are usually made out of spring steel. + Carbon Fibre is a material consisting of fibers about 5–10 μm in diameter and composed mostly of carbon atoms. The carbon atoms are bonded together in crystals that are more or less aligned parallel to the long axis of the fiber. The crystal alignment gives the fiber high strength-to-volume ratio (makes it strong for its size).

What’s Inside

+ High Pressure thermoplastic urethane shank (helps stabilise the foot and efficiently transfering energy to make a leap. Gives the trainers its stiffness, ensuring plenty of support but less the weight.) + 4 layer insole high rebound EVA + 8 coiled springsMaterials

The Design

Macon blade – Became popular in the late 1950’s. Symmetrical and elliptical with a ridge-line running down the centre of the blade. + Symmetric “tulip” shape + Central spine + No Vortex Edge Fat2 Blade – a new variation of the cleaver design. + Designed to give emphasis to different stages of rowing action. Thus maximising the positive actions in the rowing shakes and minimises negative ones. + Greatest taper at tip of blade + Has the largest surface area for Vortex “sticky spoon” action

How it’s made

The shaft and blade are baked and moulded from carbon material cutting them precisely using machine + Shafts are cut into right size + Assembling the parts and gluing them together + Then undergoes a quality test + final inspection, final measurements of pitch, length, inboard and blade orientation are confirmed.


Back in the 13th century Oars were made out of wood. They were cut and carved from one chunk of a wood. Later when machines were able to cut into pieces it was them made from small chunks of wood and glued together, and more recently carbon fibre.

2 main types:

+ Macon blades + Cleaver/Big blades (new: Fat2 Blade) Blades made this way are: + Zero slip perpendicular to the blade surface. + No resistance to movement in line with the shaft; in other words, it would glide. + The ability to rotate in the water. We will define the point of rotation as the point where the blade and shaft join.

MATERIALS 2 These are the materials that I classify as unusual. The materials are innovative as they have many uses and can be manipulated in terms of dimensions and shapes. Also would be very good to experiment with the materials i don’t normally use for my practice. Like what Lawrence Lek said during an interview for Designers in Residence, materials that he uses are economical rather than using materials for their aesthetic, as it is a necessity. It is a good way of knowing your limitations basing on the costs and process of it.

Properties Optical fibre + Malleable + Hair thin (durable glass) + Light follows the structure of the material (light travelling through glass) + Conductor of energyf Wax +Malleable + Can be melted and will have low viscosity + Insoluble in water but soluble in organic + Corrosion resistance Plywood + Stiff (But can be bend by soaking into water as seen on Lawrence Lek’s Unlimited Edition Project. See below) + Can be cut into desired shapes + Smooth surface (can be made into canvas) + Can be glued and stacked to make it more durable by alternating the grain + Flexible

Processes Being able to be bundled with loads of fibres and can let light pass trough it, it can be made into a wearable material. As Lawrence Lek’s project is depiceted one piece doesnt mean anything until you join them together.

The most common property of wax that i noticed is that it can be melted and turn into a liquid state and can be molded, as well as sculpting because of its softness when near melting point.

A very good property of plywood thst I just discovered is how it cn be bend by soking it in water. Yet hardens back again once dried and retins its shape. Can be used with laser cutting to cut intricate shpes. Combinging wax with plywood it will proveide the mold base for the wax. Cutting it into desired shapes as a base.

The Godfather by Jeff Feligno Made from Castilene which is a wax and clay mix

Wax is a class of chemical compounds that are plastic (malleable) near ambient temperatures. Characteristically, it melts above 45 degree Celsius (113 degrees Fahrenheit) to give a low viscosity liquid. Waxes are insoluble in water but soluble in organic, nonpolar solvents. All waxes are organic compound, both synthetic and naturally occurring. Again, a kind of material that we see or have used many times.

Sneaker Head by Aske Sicksystems Synthesizes elements of Soviet era cubism, constructivism and futurism through vector art into semi-sculptural works of art.

Plywood is a manufactured wood panel made from thin sheets of wood veneer. It is one of the most widely used wood products. A material that can be cut into. And can be processed, have many potential outcome. It has characteristic of either being flexible or soft, and stiff or hard.

Unlimited Edition by Lawrence Lek Optical fibre is a flexible transparent fibre made of glass (silica) or plastic. Almost the diameter of the human hair. It has a unique property called “Total Internal Reflection”, where it can bend light. The source of light travels straight until it hits the interface between the material and air. Other interesting properties of the optical fibre is that its malleable. Hair thin yet durable when bundled together. allows the light to follow its structure or shape.

Lumi Tops by Lumigram Taking advantage of the fibre optics’ thread like property and creating it into a wearable object.

DESIGN DEVELOPMENT 3 The material that I decided to research and experiment more is wax. It has many interesting characteristic and potential outcomes when mixed with more different substances like flours, salt, and bicarbonate soda. I have mixed this things together to make an outcome and even a new material to be developed into something else. These experiments lead me to gain more knowledge about wax and how simple properties can be applied and combined with different things. And how transformation of the wax affect the other material being applied to.

Collected Works Duffle Backpack A Kickstarter project that has inspired me to research more about wax canvas and its process. By allowing th e wax to impregnate into the fabric makes the fabric water repellent.

DESIGN OUTCOME 4 After the series of experimentation with candle wax I have come up with a design solution. The Duffle bag by Collected Works Co. has really inspired me to create this water repellant material. I thought if I could use the wisdom that I learned from Lawrence Lek I would use paper rather than fabric. In this way I am not just creating or showing how to make a wax canvas but making a different material. Using the same process of impregnating the wax into the fabric. A property of a wax that I just completely took for granted is that melted wax is liquid. In this form the wax can go inside the paper and settles inside thus making it not just water repellant but also water proof. On Lek’s Unlimited Edition project his process of making the prototype of his modular plywood objects is by using paper and forming them. For this design outcome paper would be perfect as it is easy to manipulate the shapes or form of the paper and has stiffness quality making it perfect for folding. The design outcome is recreating objects that are water repellant by using the new material or objects that we think it should be water repellant or waterproof. These things are the everyday objects we see and use. And in the UK we all know how very unpredictable the weather can be and having this water repellant can be very helpful.


Potential Use

The material I used for this one is a candle wax, 300 gms sheet of card, and a blow dryer. To impregnate the card melt the wax using the blow dryer and spread it on the paper. At first lump of wax is going to gather on the paper, I just use the dryer to blow it on another direction. After the impregnation stage, I used a paint roller, with a foam like texture to it, to spread the wax evenly and making the texture smoother. THis also allows the roller to soak up the excess wax.

The examples shown in this board is just the simple solutions of everyday things that we use everyday. The potential shapes of the paper and stitching can be done trough a laser cutter and an automatic sewing machine. The availability of the materials used is very economical making it very affordable to make. And by mixing the wax into the paper the new material is sturdier and water repellent making it useful during rainy season.

The chocolate brown card with the wax applied to it gives it this leather look to the material. By applying super glue and stitching, helps seal all the gaps of the card.

Thie idea of the book cover is to have a solution on comuters where sometimes they use books as an umbrella from the rain. Having this book cover, not only protects the user from the rain but also the book from being damage

Handmade HighTech - Design Museum  
Handmade HighTech - Design Museum  

A brief for the Design museum in london.