00 PROJECT Page Title
D
Bob Holt 8
7
6
50,5
F
5,0
16,8
5
4
3
2
1
F 1.0 A C
7,5
99,5
35,5 15,0
24,3
C 8
7
6
5
4
3
2
1
F
F
50 mm
94 mm
E
E
3 mm
D
21,9 mm 2 mm
D
+0,2 1 - 0,1 mm 4x
50 mm
0.05 A B
C
C 31,4
O DETAIL N SCALE 4 : 1 PCB mount groove
B
O
A
17,7
+0,2 3,7 - 0,1 mm
B
13
B
34 CAD IS MASTER
FINISH:
•Overmould: PM-T1: Light bead blast •Substrate: SPI-A2: High Gloss GENERAL TOLLERANCE:
A
7
MATERIALS:
5
4
WEIGHT: 31.15 g
3
REVISION DATE
Bob Holt TITLE:
10/04/18
Housing Top
DWG NO.
•Substrate: Apec 1603 Covestro Polycarbonate •Overmold: Versollan OM 1255NX-1 TPE
6 mm
6
DRAWN
±0.25mm
SECTION O-O Through boss section
DETAIL P SCALE 2 : 1 Through boss detail
8
SOLIDWORKS Educational Product. For Instructional Use Only.
GuyLight
SCALE:1:1 DIMENSIONS ARE IN MILLIMETERS
2
A A3
SHEET 7 OF 8
1
E
10,0
E
20,0
B
20,0 17,5
17,5
D
3,0 ±0,2 TYP 0.2 A
2x
1.0 C
5,0 A
+0,08 5,41 0,00 0.2 A C
+1,0 6,0 0,0 1.0 A B
7
6
5
4
3
2
Button inserted from side
E
15 10 F
E
Joining battery contact joined with small tack of epoxy.
D
D
Tabs on batter contacts should be bent over once through holes.
C
B
B DO NOT SCALE DRAWING
REVISION
DRAWN
DATE
Bob Holt
A
Notes: •Button inserted from side, tollerance fit. •Positive battery contact folded and soldered to button contact. •2 x PCB positive contacts soldered to other contact of button. •2 x PCB negative contacts solder to negative battery contact.
8
7
6
SOLIDWORKS Educational Product. For Instructional Use Only.
26/04/18
TITLE:
Electronics sub-assembely A
DWG NO.
5
4
3
GuyLight
SCALE: 3:2 DIMENSIONS ARE IN MILLIMETERS
2
25
14
F
C
15
20,0 2.0 A B
14
1
F
D
1.0 B
15
C 8
3,0 ±0,2 TYP 0.2 A
2x 1.0 A B
A3
SHEET 5 OF 8
1
B
21
Design Engineering Portfolio 7
18 41
25
B
25
50 D
G QUANTITY:
1
Copyright © Bang Creations Ltd, All rights reserved
A
8
20
47
2 x 90° TYP
C
GENERAL TOLERANCES
E
PART NUMBER & TITLE
DOCUMENT TYPE:
MATERIAL:
LAST REVISED: 12 March 2019
P101-V1 GENEVA BOX (GEOMETRIC)
Component
A3
Pre-Galvanised Steel - 0.7mm
(UNLESS OTHERWISE STATED)
LINEAR ANGULAR SURFACE
= ± 1.0 mm = ± 2.0° = ± N/A mm
DIMENSIONS ARE IN mm
6
5
4
DRAWN
SCALE:
1:2 NAME
DATE
BOB HOLT
11/03/2019
A
FINISH:
N/A
APPRV'D
3
2
CAD IS MASTER
1
SHEET 1 OF 1
SOLIDWORKS Educational Product. For Instructional Use Only.
SECTION D-D SCALE 1 : 13
1
01 GUIDE LIGHT
A stylish, & rugged lighting solution to prevent accidents at evening & night while camping: By Illuminating guy ropes. Using low power LED technology for an extensive 14 week battery life. Fully designed for manufacture and assembly, using ‘off-the-shelf’ components where possible to maximise cost efficiency.
2
01 GUIDE LIGHT
Ideation & Development
8
7
6
5
4
3
2
1
F
F
50 mm
94 mm
E
E
3 mm
D
21,9 mm 2 mm
D
+0,2 1 - 0,1 mm 4x
50 mm
0.05 A B
C
C 31,4
O DETAIL N SCALE 4 : 1 PCB mount groove
B
O
A
17,7
+0,2 3,7 - 0,1 mm
B
13
B
34 CAD IS MASTER
FINISH:
•Overmould: PM-T1: Light bead blast •Substrate: SPI-A2: High Gloss GENERAL TOLLERANCE:
A
7
8
7
6
5
4
3
2
MATERIALS:
5
4
WEIGHT: 31.15 g
3
REVISION DATE
Bob Holt TITLE:
10/04/18
Housing Top
DWG NO.
•Substrate: Apec 1603 Covestro Polycarbonate •Overmold: Versollan OM 1255NX-1 TPE
6 mm
6
DRAWN
±0.25mm
SECTION O-O Through boss section
DETAIL P SCALE 2 : 1 Through boss detail
8
SOLIDWORKS Educational Product. For Instructional Use Only.
GuyLight
SCALE:1:1 DIMENSIONS ARE IN MILLIMETERS
2
A A3
SHEET 7 OF 8
1
1
F
F
Button inserted from side
E
E
Joining battery contact joined with small tack of epoxy.
D
D
Tabs on batter contacts should be bent over once through holes.
C
C
B
B DO NOT SCALE DRAWING
REVISION
DRAWN
DATE
Bob Holt
A
Notes: •Button inserted from side, tollerance fit. •Positive battery contact folded and soldered to button contact. •2 x PCB positive contacts soldered to other contact of button. •2 x PCB negative contacts solder to negative battery contact.
8
7
6
SOLIDWORKS Educational Product. For Instructional Use Only.
26/04/18
TITLE:
Electronics sub-assembely A
DWG NO.
5
4
3
GuyLight
SCALE: 3:2 DIMENSIONS ARE IN MILLIMETERS
2
A3
SHEET 5 OF 8
1
3
01 GUIDE LIGHT Exploded Assembly TPE Overmoulded PC Housing
Polycarbonate housing with a TPE overmould, providing grip and a seal around the screws.
4 x M2.5x25mm Plastite Screws Plastite screws reduces the stresses caused by screwing into bosses. And reduces tear-out.
2 x AAA Batteries (included) Sourced batteries, included with the design so it works straight out of the box.
Rubber housing seal A silicone rubber seal, which provides water resistance to the light.
2 x PCB 2 PCBs with 1.1kOhm resistors and 1mA LEDs.
Battery contacts Sourced battery contact components, with folding tabs for fixing and soldering.
2 x M2.5x6mm Plastite Screws These screws attach the inner mounting plate for the batteries and button to the housing.
TPE Overmoulded PC Housing Overmould has button features moulded in: Stress reduction groove around the button and on/off detailing.
Button switch Sourced button switch. 4
01 GUIDE LIGHT Materials & Tooling
The overmoulded housing components are designed using uniform wall thickness, ribs, and fillets for optimum melt flow.
Housing Polycarbonate Substrate Mould Tool
Housing TPE Overmould Tool
Injection tunnel gate
Thermoplastic Elastomer (Versollan OM 1255NX-1)
Polycarbonate (Covestro Apec 1603)
Cavity mould
3rd mould tool
Core mould
Ejector pin
Materials: Clear PC substrate: •Apec 1603 Covestro Polycarbonate. •UV stabilised. •High viscosity. •0.75% uniform cooling shrinkage.
Green TPE Overmould: •Versollan OM 1255NX-1 Thermoplastic Elastomer. •Chemically adheres to Apec 1603 Covestro Polycarbonate •Smartbatch Colouring Concentrate from PolyOne with UV stabilisation. •0.7-1.3% cooling shrinkage.
Finish: SPI-A2: High Gloss
Finish: PM-T1: Light bead blast
5
01 GUIDE LIGHT Engineering Analysis
Draft Analysis
Mould Flow Simulations
These draft analysis simulations provide an insight into mould performance. Ensuring that the components can be easily ejected from the mould. Preserving tool life, and ensuring production viability.
Using SolidWorks Plastics I evaluated potential areas susceptible to sink marks. In this simulation there aren’t any parts with high risk, and parts with potential for sink aren’t significantly cosmetic.
6
6
00 02 PROJECT EVACLITE Page Title
While on my industrial placement as a Product Design Engineer, I worked on a project for our client Evaclite. They came to us wanting a series of housings for their disruptive new technology: A live feedback, dynamic emergency exit system. I was tasked with designing the housing for their high-end model; Monaco. It had to have a metal exterior, with minimal or no visible fixings.
7
02 EVACLITE
Technical Development Concepts of assembly options
Iteration 4: Full assembly with sandwiched sheet
Iteration 1: Single casting
Iteration 2: Sliding castings
Iteration 3: Screwed castings
Iteration 5: Full assembly with screwed castings
8
02 EVACLITE
Iteration 8, 9, & 10 8 - Extrusion based
10 - Sandwiched bent sheet
9 - Casting joints and universal extrusion
Iteration 8 was not able to rotate which made it unsuitable for purpose, as it wouldn’t display well on angled ceilings. Also, using a large extrusion for the main body had cost implications with post processing. The next version was good, but the split lines between components will not look as good as in renders, also there is a high component count which isn’t ideal for assembly. Iteration 10 was the penultimate concept, the aesthetic of this was taken forwards into further detail design.
9
02 EVACLITE
A Selection from the Prototyping Process Cardboard proof of concept prototypes (left), experimenting with DfA, and how someone on the assembly line may need to wire and feed electronics though the housing. The pre-production prototype (bottom left, and centre) which came back from our manufacturer. There were details to fix, such as large gaps between components and the manufacturer inability to partially drill though thin sections, leaving ugly holes. Rough prototypes for testing on-site installation experience Initial pre-production prototype
A showroom prototype (bottom right) taken by the client to Dubai for a conference in which they won investment, industry support, and product orders.
Hinge detail - Issues with join alignment and aesthetic finish. Requires design alteration.
Showroom prototype
10
02 EVACLITE
Now in Manufacture
A closer look at a plastic component:
The component below holds the PCB which holds the LEDs, connectors, & ICs. It also has built in plastic ‘springs’ which push the graphic panels into the frame, allowing for a large clearance, but a perfect alignment with the aluminium frame. This component also attached the main frame to the suspended arms.
PCB Holder component, built in springs, and FEA analysis
11
02 EVACLITE
GD&T Engineering Drawing
8
7
6
50,5
F
5,0
16,8
5
4
3
2
1
F 1.0 A C
7,5
99,5
35,5 15,0
24,3
C
E
10,0
E
20,0
B
20,0 17,5
During this project I also designed the electronics housing for the lower-budget recess version of Evaclite.
17,5
D
3,0 ±0,2 TYP 0.2 A 1.0 C
2x
5,0 A
+0,08 5,41 0,00 0.2 A C
3,0 ±0,2 TYP 0.2 A 1.0 B
2x 1.0 A B
+1,0 6,0 0,0 1.0 A B
D 15
20,0 2.0 A B
14
15 10
15
C
F
21
C
20
18
47
2 x 90° TYP
B
I designed the component using SolidWorks sheet metal.
25
14
D 1
Copyright © Bang Creations Ltd, All rights reserved
A
B
25
QUANTITY:
GENERAL TOLERANCES
E
PART NUMBER & TITLE
DOCUMENT TYPE:
P101-V1 GENEVA BOX (GEOMETRIC)
Component
A3
MATERIAL:
= ± 1.0 mm = ± 2.0° = ± N/A mm
DIMENSIONS ARE IN mm
8
7
6
5
4
SCALE:
1:2
LAST REVISED: 12 March 2019
Pre-Galvanised Steel - 0.7mm
(UNLESS OTHERWISE STATED)
LINEAR ANGULAR SURFACE
The engineering drawing uses GD&T to the BS 8888 standard.
41
25
50
G
This engineering drawing is for the Evaclite Vienna’s electronic housing box.
DRAWN
NAME
DATE
BOB HOLT
11/03/2019
A
FINISH:
N/A
APPRV'D
3
2
CAD IS MASTER
1
SHEET 1 OF 1
12
02 EVACLITE
Page M echanism Title Versatility
Recess
High ceiling
Standard ceiling
Wall Angled
13
00 PROJECT 03 ARDUINO Page Title
In a university project my partner and I created an automated kitchen growing station for herbs. The growing station included a gravity-fed watering system with live feedback on soil hydration. The design revolved around giving feedback on money and carbon emissions saved from growing their own herbs, encouraging behaviour change.
14
03 ARDUINO Product features
Key components used: 1 x WiFi101 module - WiFi connection to allow push notification to mobile phones when water tank is empty. 2 x Moisture sensors - Send feedback on soil moisture level for watering. Second sensor gives feedback on water reservoir level. 1 x LCD display - Gives user feedback on cost and CO2 savings. Controls for setting watering level. 1 x Servo - Used to control water flow through a crimp valve.
LCD display and button controls.
Water reservoir with sensor to notify user if empty.
Valve closed
Valve open 15
00 PROJECT 04 DRONE Page Title
A final year university project for Computational Mechanical Design: A redesign of the common F450 DIY drone frame using topology optimisation. Providing a weight reduction of 60%. While maintaining existing manufacturing methods (injection moulding).
16
04 DRONE
Design & Development
Design process: 13.2N 0.5Nm
Define preserves & voids
Specify constraints & loads
Generate multiple outcomes
Iteration 1 - Too chunky
Iteration 3 - Boss hole issues
Iteration 12 - Boss hole issues
Iteration 16 - Manufacturability issues
Iteration 17 - Strength issues at bosses
Iteration 20 - Minor refinements needed
Export & selectively re-model
Iteration 21 - Selectively remodelled for injection moulding.
17
00 PROJECT 05 OPLOFT Page Title
Our client; Posturite, came to us with a challenge to create a highly ergonomic and safe storage rack to store compact sit-stand desks in an office.
18
05 OPLOFT
Proof of Principle & Ergonomic Testing
Undesired ergonomic interactions. We created a rough wooden rig to investigate the anthropometric sizes that we chose for the storage platform. We found that taller people would lift the desk straight up, which is not desired due to lower back strain. To counter this we added arrows onto the top of the design to indicate use, this was found to be more effective than simply limiting the range of movement of the desk.
Desired user interaction
Initial rough rig
Issues with interaction of tall people 19
05 OPLOFT Production
Quality control Manufactured locally in Bristol, once the first few finish products came off the line, I went to the manufacturing facility to check sizes and tolerance were in line with the engineering drawing pack that I made and sent to them.
Checking tolerances to my engineering drawings
First production run
Ready for shippi 20
06 IN-SPACE
This project was contracted by In-Space Missions LTD. I was tasked with engineering a 1U ring for their new satellite: Faraday. Using topology optimisation I created the lightest possible design, without compromising the components strength. The satellite is due to be launched in 2020.
21
06 IN-SPACE
Topology Studies & FEA
Flight data from the rocket was used to calculate the forces in which the component would be subject to: Material: Axial load: Lateral load: Force: Force location: Fixing locations: Load cases:
6061 Aluminium alloy +8/-4 G Âą2G 160 N (Total) Inner bolt holes. 4 corner bolt holes. 2
FEA Validation After I designed the ring from the topology studies, I used FEA to verify the design.
22
00 PROJECT 07 BRAND Page Title
The brief: “To design a product for The Guardian, without an existing physical identity. This product must reflect the brand’s purpose, identity, and personality.”
The project began with extensive brand research and analysis. This information was distilled into 4 semantic drivers. These semantic drivers were then resolved into material textures, form factors, and surface finishes.
BLUETOOTH®
LISTEN.
WATERPROOF
TRAVEL.
TWIST ON/OFF
PLAY.
23
07 BRAND
Initial Concepts
Initial ideas, based upon the semantic drivers, and form factors identified from research analysis.
24
07 BRAND
Electronics & PCB
The speaker has a twist action which acts as on/off switch as well as volume control. This is achieved using a dual-gang switch potentiometer, which is connected to the L/R input from the Bluetooth receiver module. The potentiometer is not included on the PCB. The below schematic is for the receiver module and amplifier circuit. Altium Designer was used to create this PCB, which I had manufactured in China for USD$1 each.
25
00 PROJECT 08 LIVE Page Title
The brief: “Design a new product around the area of ‘walking dogs with a lead.’ for the medium to mass market. The design should be in keeping with the clients brand and ethos; the product or products should empathise with both the human and the animal, be intuitive, highly functional and stylish.”
26
08 LIVE Ideation
Following our research and analysis we used procedural ideation methods to create innovative ideas. Using sketching and some initial low fidelity prototypes. Then using critical analysis identified ideas worthy of further development.
27
08 LIVE
Development & Testing
Elastic reel mechanism
+Loop round wrist for security
+Ergonomic considerations
+Integration of 2nd handle
+Mechanism consideration
+Further ergonomic considerations
Cutaway view of internal mechanism:
28
00 PROJECT 09 PEPSI Page Title
During my time in work at Realise-Live as a Junior Design Engineer, I was asked to design a giant 3m tall Pepsi Can; to promote Pepsi’s release of their new soft drink: Pepsi Max Ginger. I had the opportunity to work with a fantastic group of people... •Working directly with clients •Managing and working with the workshop on the production of my design. •Project management, to help me structure my project, and relay any information from clients. •The Senior Design Engineer, who would check on my designs, to ensure they were of high quality.
29
09 PEPSI The Brief
Design requirements: •Able to be moved by 3 people to multiple locations across the country •House an interactive vending machine •Include speakers, LED lights, and smoke machine. •Fit within their budget. •Be modular with easy access to the smoke machine.
Internal LED lighting
Cutaway to show structure
Five main parts 30
09 PEPSI Production
The can was made from CNC’d MDF and 3D CNC’d medium density modelboard. The parts were assembled as per the drawings I made: A MDF frame with slots for the modelboard, doing this gave maximum cost efficiency. The component was then filled, sanded and sprayed. The spray coating was to provide an extra clean finish for the final stage: vinyl wrapping.
31
00 PROJECT Page Title
THANK YOU.
bob.holt@live.co.uk
www.linkedin.com/in/bob-holt/
07387585633 32