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Bob Holt

Design Portfolio

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01 GUIDE LIGHT THE 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.

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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

Electronic joining cables omitted for clarity.

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.

Button switch Sourced button switch.

44

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.


01 GUIDE LIGHT Engineering Analysis

Mould Flow Simulations

Simulations used to optimise product lifespan, performance, and reduce manufacturing defects.

Draft Analysis 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.

Shear stress resulting from cooling of plastic flow. In this simulation the stresses don’t concentrate on the screw bosses, reducing chances of failure during insertion of screws.

Flow rate simulation. Shows the fill time with blue being initial and red being the last part of the mould to fill. Important to check there is good flow through the guide rails.

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.

Another flow rate simulation resulting in a shot time of 1.60s. This simulation has a good even fill time, reducing the chances of additional stress build up.

A final simulation on shear stress caused by cooling of plastic flow. This stress build up isn’t in an area which particularly experiences stress during use.

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01 GUIDE LIGHT

8

7

6

5

4

ITEM NO. 1

2

E

2

4 3

3

4

5

D

7

6

7

C

8

1

4

3

2

8

1

DESCRIPTION or PART SOURCE

Button

Injection molded PP

1

Plastic push button with metal contacts

1

Steel battery contact, positive

1

Steel battery contact, joining

1

PCB Board

PCB Board with 1mA SMD LED and 1.1kOhm SMD Resistor - PCB

2

A2 Stainless steel plastite screw

4

A2 Stainless steel plastite screw

2

AAA battery, 1200mAh, 1.5V

2

MATERIALS:

7

6

8

5

WEIGHT: 61.3g excluding batteries

4

7

3

E

E

6

5

0.1 C D

2x

3

2

1

F

7,3

C

E 13

37,5

D

D

D

+0,2 12,1 - 0,1 mm

17 mm

4,5 mm

DO NOT SCALE DRAWING

DATE

Bob Holt

10/04/18

DWG NO.

GuyLight

SCALE:1:1

C

26 mm

1,5 mm

B

B

B

±0.25mm

+0,1 0,8 - 0,1 mm

A

A

A3

CAD IS MASTER

FINISH:

PM-F0: Non-cosmetic

GENERAL TOLLERANCE:

MATERIALS:

8

1

7

6

5

SOLIDWORKS Educational Product. For Instructional Use Only.

5

4

WEIGHT: 40.0g

4

3

3

REVISION

DRAWN

DATE

Bob Holt

10/04/18

TITLE:

Inner mount plate

DWG NO.

GuyLight

Edgetek PP 402S GR382

SHEET 1 OF 8

2

6

12,5 mm

C

+0,1 1,9 - 0,1 mm

Exploded BOM

TITLE:

C

REVISION

DRAWN

SCALE:2:1 DIMENSIONS ARE IN MILLIMETERS

2

2

A

A3

SHEET 8 OF 8

1

1

F

94 mm 76 mm

F E

S

F 4 mm

E

S

0,5 mm

SECTION S-S

41,5 mm

D

DETAIL U LIP / GROOVE SCALE 5 : 1

E

50 mm

C

C

T

C

U

6

SOLIDWORKS Educational Product. For Instructional Use Only.

8

7

6

5

4

5

30/04/18

WEIGHT: 61.3g excluding batteries

SCALE:1:1

GuyLight

A A3

SHEET 2 OF 8

2

3

D

Assembely

DWG NO.

3

4

Bob Holt

MATERIALS:

•Polycarbonate (PC) •TPE •Polypropylene (PP)

7

DATE

TITLE:

DIMENSIONS ARE IN MILLIMETERS

A

DRAWN

1

2

C

50 mm

13

B

1

SECTION C-C Nominal wall and overmold thickness

1,7

D

+0,1 0,8 - 0,1 mm

11,3

F

E M

D

A

DETAIL F SCALE 4 : 1 Mount slot for PCB

M

1,2 mm

15,7

E

F +0,2 1 - 0,1 mm

A

D

B C

DETAIL H SCALE 4 : 1 Lip feature

D

+0,1 2,9 - 0,1 mm

C 6x

C

Notes: Screws to be inserted with driving torque of 0.9Nm

SECTION M-M SCALE 1 : 1

DRAWN

DATE

Bob Holt

10/04/18

DETAIL D Boss detail SCALE 3 : 1

A

TITLE:

Housing sub-assembely A

A

DWG NO.

8

7

6

SOLIDWORKS Educational Product. For Instructional Use Only.

5

4

3

SCALE:1:2

GuyLight

DIMENSIONS ARE IN MILLIMETERS

2

8,8 mm

1,2 mm

B REVISION

1

8

7

SOLIDWORKS Educational Product. For Instructional Use Only.

DATE

Bob Holt

10/04/18

TITLE:

Housing Top

5

MATERIALS:

DWG NO.

WEIGHT: 24.82 g

SCALE:1:1 DIMENSIONS ARE IN MILLIMETERS

•Substrate: Apec 1603 Covestro Polycarbonate •Overmold: Versollan OM 1255NX-1 TPE

4

3

REVISION

DRAWN

±0.25mm

SECTION A-A Boss-inserts

6

•Overmould: PM-T1: Light bead blast •Substrate: SPI-A2: High Gloss General Tolerance:

A3

SHEET 3 OF 8

CAD IS MASTER

FINISH:

H

DO NOT SCALE DRAWING

B

0.05 mm A B

4 x M3.5, 25mm Plastite screw

B

C

+0,2 2,6 - 0,2 mm

C

15,7

F

34

1 mm

•Overmold: Low gloss •Housing substrate: Clear gloss •Inner mounting plate: None

REVISION

4 mm

DO NOT SCALE DRAWING

FINISH:

8

9 mm

B

SECTION T-T SCREW BOSSES

21,6 mm

B

E

DETAIL D SCALE 4 : 1 Retaining bump

2 mm

T

R 0,5 mm

4 mm

94 mm

D

66

4

D

1

•Polycarbonate (PC) •TPE •Polypropylene (PP)

F

1

Steel battery contact, negative

DIMENSIONS ARE IN MILLIMETERS

A

1

Positive battery contact 5266 Negative battery contact 5204 Joining battery contact 5214

•Overmold: Low gloss •Housing substrate: Clear gloss •Inner mounting plate: None

9

F

7

QTY.

Injection molded PC, TPE overmold, multiple finishes Injection molded PC, TPE overmol, multiple finishes

FINISH:

1

F

PART NUMBER

Housing Bottom Housing Top Inner mounting Plate

M3.5 x 25mm 9 Plastite screw M2.5 x 6mm 10 Plastite screw 11 AAA Battery

B

8

5

6

8

SOLIDWORKS Educational Product. For Instructional Use Only.

6

5

10

Drawings use BS 8888 standards as a guideline for formatting. Drawings are optimised for clarity of communication, and for production. BOM includes all off-the-shelf components and their sources for large volume purchases. 7

2

F

Production Drawings

8

3

2

GuyLight

A A3

SHEET 6 OF 8

1

Link to full drawing pack: https://issuu.com/bob-holt/docs/guylight_assembely?e=33207637/60977968


01 GUIDE LIGHT

Pre-Production Prototype This initial functional prototype was made using a Formlabs SLA resin 3D printer on a 25 micron layer height print setting. The design was made using all the manufacturing components to be used in the final design. Using this functional prototype I evaluated any necessary changes to the tolerances in the design, so that it can be injection moulded with maximum consistency.

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01 GUIDE LIGHT

Tooling Diagrams & Materials Polypropylene: •Edgetek PP 402S GR382 Polypropylene. •1.2-1.8% shrinkage. •High viscosity for injection moulding. •Low cost.

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: PM-F0: Non-cosmetic

Finish: SPI-A2: High Gloss

Finish: PM-T1: Light bead blast

Inner plate mould Housing Polycarbonate Substrate Moulds

Housing TPE Overmould Tools

Injection tunnel gate

The overmoulded housing components are designed using uniform wall thickness, ribs, and fillets for optimum melt flow.

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Polypropylene (Edgetek 402S)

Injection tunnel gate

Thermoplastic Elastomer (Versollan OM 1255NX-1)

Polycarbonate (Covestro Apec 1603)

Cavity mould

3rd mould tool

Core mould

Ejector pin / stripper plate


GUIDELIGHT A stylish, & rugged lighting solution to prevent accidents at evening & night while camping.

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02 PEPSI MAX INTERNSHIP 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.

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02 PEPSI MAX The Brief

This giant can had to be: •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.

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02 PEPSI MAX Technical Design

To create this design I was given a Pepsi can, the brief, and some stationery. From here I went through a series of sketches and ideas with the Senior Design Engineer on what the best way to approach the problem was. Next I produced the design on SolidWorks, problem solving and detailing on the way. The main issue to contend with was creating the cylindrical outer skin, and making sure it didn’t peel off. This was solved with double supports near ending edges to fix into. In total there were 198 components. All working to a tolerance of 0.3mm

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ructional Use Only.

SOLIDWORKS Educational Product. For Instructional Use Only.


02 PEPSI MAX 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.

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03 GUARDIAN BRAND DESIGN The brief: “To design a product for a given brand 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.

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03 GUARDIAN

Research & Analysis

Following my research, I identified the main target audience for The Guardian as being: Intelligent, well travelled, with strong social morals.

Form Factors Identified from Personality Traits

Following this, brand personality traits we’re identified using concept mapping and brand platform analysis:

Intelligent 40%

Circular

Rounded

Honest 30% Diverse 20%

Subtle Recess

Playful 10% Crisp Edges

Modular

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03 GUARDIAN Initial Ideation

Initial ideas, based upon the semantic drivers, and form factors identified from research analysis.

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03 GUARDIAN

Design Development

A small selection of sketches and CAD renders from the development process.

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03 GUARDIAN

Electronics Schematic 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. This potentiometer is not included on the PCB. The below schematic is for the receiver module and amplifier circuit.

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BLUETOOTH®

LISTEN.

WATERPROOF

TRAVEL.

TWIST ON/OFF

PLAY.

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04 LIVE LIVE PROJECT

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. .

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04 LIVE

User-Centred Research During our research we used a combination of techniques:

•Primary observations - We went on a dog walk with Clare to passively observe her dog walking experience. •Primary Experiences - We also borrowed a dog to go on walks with, to build empathy and create and understanding of our users needs and problems. •Primary surveys - We used online surveys to further explore the problems encountered by our target users. •Secondary research - Statistical analysis, anthropometrics, and more. Used to further support our research. Problems identified from research: •Lack of security and control by roads •Difficulty taking the dog off and on the lead. •Uncomfortable grips which may lead to hand strain. •Wrapping leads around hands to shorten the length by roads

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04 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.

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04 LIVE

Development We used a variety of techniques to develop our idea into reality... •Thermoplastic modelling •Rapid prototyping: FDM & SLA printing. •High density foam modelling •CAD: SolidWorks •Plasticine modelling •Hacks on existing products

Initial prototype

+Loop round wrist for security

+Ergonomic considerations

+Integration of 2nd handle

+Mechanism consideration

+Further ergonomic considerations

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DuoSafe

the double grip dog lead

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THANK YOU.

bob.holt@live.co.uk

www.linkedin.com/in/bob-holt/

07387585633

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Product Design Portfolio - Bob Holt  
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