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D E S I G N P O R T F O L I O Carla Urbano Valero

EDUCATION 2015 2019 Meng Design Engineering Imperial College London WORK EXPERIENCE 2017 Lumilight - entrepeneur 2017 Selfie Sticks - videogame SKILLSET Graphic Design Affinity Designer InDesign Illustrator CAD & 3D Solidworks Fusion 360 Design Sketch Product design Workshop Woodwork and metalwork Model-building and prototyping Painting and surface finishing Coding Python Matlab Electronics and Robotics Circuit design RaspberryPi Arduino LANGUAGES First language Spanish Fluent English Basic French

Hello! This is Carla, Spanish girl currently living in London. I am a third year student of Design Engineering at Imperial College London. Design for me is the perfect combination of creativity and problem solving, which are two of my biggest passions. I consider myself as a creative, passionate and outgoing person at the same time as hard-worker and dedicated, liking to fucus on details which make designs outstand. I am always happy to be challenged with new projects, specially group ones where I am able to provide my skills as well as learning from other people’s ones. I am currently looking for a six months placement in order to broaden my knowledge and to challenge myself to solve new problems.











01 The challenge set was to combine design and technology to create an electromechanical machine that generates sound. The team had to design, build and demonstrate at least one machine that effectively integrated machine elements, sensors and actuators and software to perform a specified function. It was not necessary for the final outcome to fulfil a real-world need, allowing space to make it playful and creative with the only limit set being the given budget of ÂŁ100.

THE PROCESS Brainstorming sessions were performed to boost creativity from the beginning. The final idea became a drum kit that included three different elements, a bass drum, snare drum and cymbal, each controlled by a different mechanism and a controller with multiple switches for the user to interact with. Several mechanisms were considered and prototyped.

FINAL PROTOTYPE THE MECHANISMS Two main mechanisms were developed for hitting the percussion instruments, one for the snare drum and one for the base drum, each actuated by a solenoid motor. The mechanisms were first prototyped low-fidelity, using cardboard, plywood and string. Basic CADs were then created, and SolidWorks motion studies were used to define their dimensions. Parts and links were laser cut and iterated, before the final mechanisms were assembled. The user interaction was created through a controller that worked similar to a step sequencer via a RaspberryPi.

The final concept of the project was to have a beautiful yet simple design that generated sound using percussion instruments. The group agreed on the idea of a unique experience and it being interactive so that each user could have a different output, using LEDs to enhance the experience. The final outcome is a nice combination of computing, electronics and mechanics.



02 Winner of the Design Engineering Selected Innovation Reward (DESIRE Award) Spiro is a medical device designed to measure various lung capacities such as Tidal Volume and Residual Volume. The device is designed to be operated in low-income countries. The design was human centred and considered many environmental factors.






USER RESEARCH Lack of data in low income countries. Even though there is no reliable data about lung diseases, it is well known that countries in Sub-Saharan Africa still use solid fuels for indoor cooking. All countries in Sub-Saharan Africa are eligible in the ODA (Official Development Assistant)


USER NEEDS Huge range of locations and climates the device is to be used in, device needs to withstand large temperature ranges. It must be dust and water resistant. The device will take advantage of the high intensity of sun being powered by solar panel. Device must be portable.

HANDLE PROTOTYPE A look-a-like model was manufactured to demonstrate the aesthetics of the design.The main focus given to the handle was the comfort the user would have during the tests. To explore different shapes, blue foam and clay were used to find the perfect shape. The handle was provided with an angle to allow for a neutral hand position while keeping a the turbines in a horizontal axis. Blue locating features were added for a more intuitive use.

U S E R V A L I D AT I O N The final prototype was made by CNC milling chemiwood and sptray painted to give a shiny, smooth finish. These early prototypes were tested with users of different hand shapes in order to verify the comfort of the handle. Feedback was positive, providing a comfortable grip for hands from 5th to 95thpercentile of hand sizes.

HANDLE CAD This design has many in-built features to minimise the spread of pathogens between patients. The handle itself has been designed to facilitate large scale manufacture. It is composed of 2 shell halves which snap fit together.

Push fit for residual volume attachment Locating recess turbine module


Push fit for mouthpiece

Integrated O2 carrier tubing

Snap fit holes and pins Draft angles of at least 2 degrees O-ring seal

HYGIENE The whole device was designed around the idea of being able to use it for several days outside of a hospital. This required reusability of every component and easy disassembly of the product.

SOLAR PANEL Use of solar panels as main source to get advangate of climate and to save energy.

MODULARITY The whole device is laid out to clarify to the nurse how it should be used. The spirometer handle is placed in the centre of the case since it is the most important component. The residual volume attachment is placed on the left hand-side showing how both components should be connected.

BATTERIES Two batteries are found at the left bottom of the case to power the whole device and screen. One of them would charge with the solar panel and the remaining one will provide the power.

PORTABILITY The case chosen was similar to a pelicase in order to endure the environmental conditions such as high temperatures, dust ingress and security.

INTERFACE Interface on right hand-side with easy communcations and language settings.

WORK-A-LIKE PROTOTYPE The working prototype demonstrated how the expired and inspired volumes would be measured by the patients. A small turbine was mounted on an axle within a tube. Magnets were attached to each blade of the turbine. A hall effect sensor mounted in the casing of the turbine detected every passing of the magnet as a pulse. Thefrequency of these pulses was translated into a flow rate which returned the expired and inspired volume. An Arduino was used to process the data.



03 An autonomous vehicle designed for the busy city of Shanghai. The intention of the vehicle is a contribution to a solution for the condensed traffic of these polluted city and in order to innovate with greener technology and provide businessmen with a space to work or unwind.

SHANGHAI In order to fulfil our vision and satisfy the specifications the team came up with a design that offers a comfortable and clean environment, that makes the pod feel spacious and utilises modern technology. After studying the demographic of Shanghai, illustrating its ethnic diversity, anthropometric data for both the largest and the smallest user groups informed the dimensions of the whole design.

easy communication translation option for turists

comfort relax environment for businessmen

Legroom to allow wheelchair

reduced sufficient space


extra space for luggage and wheelcharis

inclusivity accesibility for elderly and disabled

Adjust height of seats informed by testing over the anthropometric values

FINAL PROTOTYPE A real-size prototype was built to prove the comfort of the pod. The two seats are facing forwards and are able to observe the scenic city of Shanghai. The seats were spaced quite far apart, allowing a sense of personal space and privacy in these commonly lift shared vehicles. The need for personal space is inherent for a crowded city such as Shanghai. The centre module offers two individual working tables and a control panel that allows the user to interact with the controls of the pod. An interface was developed to cover all potential requirements and to be easy to use by all user groups.



04 The challenge was to redesign the handle of a personal care product, specifically a toothbrush, to improve its sustainability whilst delivering the same function and outcome. The aim was to end with linear lifecycle that fast moving consumer goods (FMCG) are predominantly subjected to. The approach taken was to find a material which allowed for a closed loop lifecycle, hence increasing its sustainability. This was achieved by the creation of a new bioplastic made from banana peels. This material would not be just made from banana waste, but also have biodegradable properties, changing the linear flow into a closed loop by composting the product at the end of its life.

USER RESEARCH User research was implemented through online surveys and interviews to experts in the field as well as a system analysis of an already existing product.

soft nylon bristles

100 % recyled PP handle

square metal pieces to hold bristles block handle grip

14 grams - light weight

curved shape designed by dentist to reach difficult places

USER NEEDS User research lead to the conclusion of having a very ergonomic design. Manual toothbrushes were found to be still more used than powered ones. A key finding from online surveys was than more than 50% of toothbrushes end up in a landfill out of which 20% could have been recycled or reused for different purposes.

DESIGN GOAL The key findings from the user research were that consumers are not concern about the sustainability or end of life of the product. The project was then focused in finding an afterlife for the oral care product in order to reduce the waste material and to create a bond with the brand.

I D E AT I O N At this point of the Design Process, the material was selected. This would be a biodegradable plastic made from banana peels. It was decided the best option to integrate the material and the design would be to have an organic shape that reminded somehow to the actual fruit.

S H A P E E X P L O R AT I O N Several prototypes were done throughout the whole project. Early prototypes were made from blue foam and clay to explore different ergonomic shapes. Once the shape was found, the product was modelled with SolidWorks and 3D printed to prove its comfort. A final prototype of the handle was made from the desired material was produced.

U S E R V A L I D AT I O N The product would offer multiple positions which are comfortable, but the three ones represented on the pictures are the recommended ones. It was concluded from users feedback to have two different sizes; a smaller one to fit kids hands and a bigger one to fit adults hands..


M AT E R I A L The selection of the material focused on the main properties desired for the new toothbrush. The main characteristics were sustainability and bio-degradability. A gap in the market was found: consumption of bananas in the UK is of 12 kg per person each year. The consumptions are really high: 5 billion bananas per year in total, out of which 1.4 million fresh bananas are thrown away every day in Supermarkets. This waste would be used for the formation of the material

Banana peel collection Expired bananas are collected from supermarkets

New palm trees Biodegradable toothbrush serves as compost for new trees to grow and produce bananas

Use for 3 months Use toothbrush until it naturally reminds the user to change it

Manufacturing Processing of banana peels to create bio-plastic

Distribution and sales Distribution and purchase should not take longer than 1 week. Purchase product online and delivered home by bicycle

PORTFOLIO NAME Carla Urbano Valero E-MAIL TELEPHONE +34 675495083 EDUCATION Imperial College London

MEng Design Engineering


Portfolio including 4 design engineering projects.


Portfolio including 4 design engineering projects.