PRODUCT DESIGN
CHARLES ELSON PORTFOLIO
CONTENTS
C.A.R.E
MATCHDAY INJECTION MOULDING
CHOP ‘N DROP LUMO
MECHANICS
C.A.R.E
A REMOTE TELEHOME MONITORING SYSTEM FOR THE ELDERLY, TO REDUCE THE NUMBER OF SERIOUS INJURIES IN THOSE LIVING ALONE. INDIVIDUAL PROJECT
12 WEEK PROJECT
THE OPPORTUNITY ‘Falls in homes are becoming more and more frequent and becoming a regular problem. With the costs of elderly homes increasing, more and more elderly people are living alone at home, and are particularly vulnerable to falls and harming themselves.’
3.64 Million
people in the UK, aged 65+ live alone.
Falls are the leading In the UK alone, 4,984 57% of people people ages 65+ died the average number cause of death among from having a fall in of incidences of fall people aged 65+. 2016, equating to 13 with harm. people every day.
THE DESIGN PROCESS
Initial concept ideation and modelling was carried out to test the form and scale of the product which allowed a visual and physical form to work to. A CAD model was also produced to test colour and various forms.
FINAL DESIGN
SCENARIO OF USE
The ‘c.a.r.e’ product is placed in the home and detects falls and sudden changes in heart-rates of the user.
If an incident occurs, a family member is notified by the ‘c.a.r.e’ app on their smartphone.
Elderly people are more vulnerable to falls in their home. Often not found and treated by family until the next couple of days.
A family member or doctor can be at the scene within minutes of the incident.
From the app, they can see a live feed of the camera, as well as call emergency services to the scene, if needed. Data collected by the app can be sent and used by doctors to examine the users health.
APPEARANCE MODEL
THE FAMILY
Those who lived in a house with multiple stories would require more than one camera, which is where the miniature camera and wall mounted camera would come into play. These three cameras would come as a set at purchase.
MATCHDAY
A SMARTCITY APP DESIGNED TO MAKE THE WHOLE MATCHDAY EXPERIENCE OF VISITING A FOOTBALL MATCH A MORE PLEASANT EXPERIENCE. DESIGNED FOR USERS OF ALL AGES. GROUP RESEARCH 12 WEEK PROJECT INDIVIDUAL DESIGN
GROUP RESEARCH
Pain points, task goals and experience goals were clearly identified from user research. These allowed a clear focus as to what an app should be focussing on. A key specification of the app is the smartcity feature, of which we decided to include a scanning feature which incorporates an educational aspect within the app.
“THE LACK OF KNOWLEDGE OF THE SPORT DISCOURAGES PEOPLE TO GO. WE ALSO FOUND THAT PEOPLE WERE OFTEN MISPLACING THEIR TICKETS.”
THE PROCESS Interviews were carried out to gather information. Here I learnt about the users pain point and task goals from which the main aspects of the app would be based around.
These initial wire-frames were tested on a user from start to finish where the main issues were pointed out. These were; the format of the app wasn’t consistant throughout and there were some unnecessary features included.
The groups research was collated and the main pain points and task goals were chosen. It was decided that lack of knowledge and loss of tickets were the main ones.
From this feedback, I developed the app focussing mainly on the design and limiting the features needed for an efficient application. These designs were again tested with a user for any adjustments.
Initial wire-frames of variations of the app were created using the pain points and task goals determined throughout research. These were used for variaitons in the layout and main features of this app.
The final wireframes were developed from the user testing and these would then be developed into high fidelity app interfaces which the user could use efficiently and easily.
FINAL SOLUTION MatchDay is an app which allows users to learn and keep on top of the football while at the match. Its main feature, ‘Scan’ allows the user to scan players or shirts using their phone, which will tell them more about the player or match as a whole. Along with this, tickets can be stored on the phone or added to Wallet on smartphones which can be used to access the stadium and reduces need of paper tickets. The Matchday section is where the user can learn more about their team, the oposition and various players in the league.
Log-in
Register
Home
Matchday
Scan
Scan Results
Tickets
The log-in page is where an existing user can sign in or register if new.
A new user can enter their details to create an account.
The home page is where the user can navigate the various features.
The Matchday feature provides information on all aspects of the league.
The user can scan a player on the pitch to learn more about them.
The scan results show the players stats from the game and the season.
Tickets are stored in the app so that they are safe.
Working Matchday app prototype can be found at the following link:
https://xmgw46.axshare.com
INJECTION MOULDING TOOL DESIGN AND DEVELOP A MOULD TOOL FOR A PROMOTIONAL WIDGET AND EMULATES PRODUCING THE WIDGET ON A MASS SCALE - A LeBRON JAMES SHOE HOLDER. 6 PERSON GROUP PROJECT
12 WEEK PROJECT
INITIAL PROPOSAL The chosen design is a sports shoe holder which allows the user to hang their shoes on the outside of their rucksack. The promotional aspect is a design for LeBron James’ - a Nike sponsored athlete - and incorporates his logo in a functional manor in order to hold the users shoes.
“The promotional aspect is subtle yet effective and works well with the use of the widget.”
Prior to the group phase, individual designs were produced, which included mould tool development from scratch, mould flow simulations and engineering drawings - these were taken forward into the group phase.
A 3D printed rapid prototype was produced prior to any manufacturing took place which raised any issues with the widget that needed to be adjusted. The final widget would be made from 2 separate pieces which slot together - this prototype showed us that the tolerance fit necessary needed to be revised as it was very tight.
MANUFACTURING PROCESS BLUE FOAM PROTOTYPE The mould tool was first tested on blue foam which determined whether everything was correct with the code and if anything needed correcting.
CNC MILLING The cavity for the mould tool was milled using an XYZ milling machine. The cavity was made oversize and inserts would fill the cavity.
INSERT MANUFACTURE The inserts were manufactured using the manual milling machines. The engineering drawings were used to make sure the inserts were made to the correct size.
GRINDING All the inserts were ground to size as this was the most accurate way of getting them to sit flush in the mould block - this was to meet the specific tolerancing of +/-0.003mm
INSERT ASSEMBLY The inserts were then placed in the mould block and kept in place using location pins.
INJECTING Once the 2 halves of the mould block fit together, the mould tool was ready to be injected and injection was carried out.
Our widget came out perfectly at the first attempt with no flashing or sink marks and ejection of the widget was simple. Multiple injections were carried out at various pressure and fill speeds to ensure we had the optimum result.
MASS MANUFACTURE THREE
ONE
FIVE
TWO FOUR
FILL TIME 1.56s
CLOSING TIME 0.31s
HOLDING TIME 1.50s PREP TIME 1.23s
EJECTION 0.70s
RADIAL LAYOUT Radial filling with 6 cavities (3 widgets) would produce 3,031,578 widgets in the time period of 160 hours per week over 3 months.
3 MONTHS 13 WEEKS 160 HOURS PER WEEK 8 HOURS MAINTENANCE PER WEEK 7,488,000 SECONDS TOTAL 233,198 INJECTIONS PER WEEK 40.8g OF PLASTIC PER INJECTION
7.41s CYCLE TIME COOLING TIME 2.06s
3,031,578 WIDGETS
FINAL PRESENTATION
BRING YOUR GAME. INJECTION MOULDED PROMOTIONAL SHOE HANGER
An A0 presentation board was required with manufacturing details and product scenario. Strong branding and information on the product was evident on the poster and was widely picked up on.
CHOP ‘N DROP
A FOLDABLE CHOPPING BOARD WHICH HELPS KEEP A STUDENT KITCHEN TIDY WHEN CHOPPING FRUIT AND VEGETABLES. INDIVIDUAL PROJECT
1 WEEK PROJECT
INITIAL PROTOTYPING
“The bin was too big and in the way when I tried to use it. The product wasn’t weighted evenly.”
SCENARIO OF USE
Cutting and peeling vegetables is often a very messy task, with waste ending up on the counter-tops and the floor.
Transporting the waste food from the board to the bin is a task within itself; often missing the bin, and is a skill to not drop any wanted food onto the floor.
Using live hinges incorporated into the design of the board, assembling the bin is extremely quick and simple.
This chopping board is very compact so can be stored in a typical kitchen drawer or cupboard.
This allows any waste in the bin to fall out the bottom into the main bin, eliminating the risk of missing the bin or wasting unwanted food.
With this board, the user can cut/peel food without the risk of any waste falling onto the floor as it can be collected using the bin provided.
The underside of the bin compartment can be opened up using the strap included.
FINAL DESIGN
Handle is used for easy transport of the product.
The top section is flat on the table and is held there by the weight of the board, along with the weight of the food on the board itself.
Bin hangs over the edge of the table and collects all the waste scraped from the board into the bin.
The bottom flap opens using the strip that holds the two pieces together. This can only be undone via hand and is strong enough to hold the weight of the waste in the bin.
The bin maintains its cubic shape via the clip that is moulded into the Polypropylene.
THE FAMILY Underside of the bin is a flap that allows waste food to fall out the bottom.
Clips moulded into the Polypropylene to allow the bin to clip together and stay as they are.
Live hinges allow the board to fold into the compartment and back to flat when needed quickly and easily.
This chopping board can be moulded in various colours to allow the user to own as a set or be bought separately. Each colour resembles a different use; meat, fish, veg or fruit.
LUMO A BIKE HELMET THAT INDICATES WHEN THE USER IS TURNING TO CREATE SAFER ROADS AND LESS ACCIDENTS. INDIVIDUAL PROJECT
5 WEEK PROJECT
PERSONA
Meet Jonathon. A 22 year old Masters Student at Loughborough University studying Economics. Jon cycles to University everyday along the road. He finds that the roads are the quickest and most direct route into his lectures from where his accommodation is in town. However, after cycling the same route up to 4 times a day, he feels that he is comfirtable enough to not wear a helmet and admitted that he rarely indicates due to lack of traffic on the roads. Seeing as the roads in England - along with the drivers can be unpredictable, Jon says that he needs something that he feels comfortable in and that keeps him safe cycling to and from Uni, as well as around town.
“Bike helmets don’t suit me and they are a hassle to put on and store away! Lights are also a problem. They often die in the middle of a bike ride without any warning!”
INITIAL IDEATION
“I feel the most use of this would come out of a helmet as this both encourages and improves cycle safety”
DESIGN IDEAS
A front lip is incorporated into the moulding at the front of the helmet which is protecting from sun and rain. Front and back lights turn on automatically at dusk.
Indicators on either side of the helmet are integrated into the design, along with a front and back light. This solves the problem of lights dying mid-cycle.
The helmet will not have any straps on it as it is tight to your head and therefore friction fit. There is also a suction pad on the back which keeps it on no matter the force applied to protect the user.
Room for ears so that they are not covered by helmet. This allows for increased comfort and can hear traffic.
A 3D printed mould would be inserted into the lining of this helmet, allowing for extra comfort and safety. This is influenced by the Carapace project.
FINAL DESIGN
Indicator on glove also illuminates.
When the pad on the thumb and inside of index finger on gloves are touched together, it creates a charge which sends a signal to the helmet, illuminating the respective indicator.
Alternative design of helmet.
Refractive back light and indicators allow for extra safety when cycling.
PROTOTYPING
A prototype of my concept was created using two accelerometers and an 18F45K20 Microcontroller. The code to allow this to work was written on MPLAB software.
Testing the code was carried out throughout the process to check the respective light would illuminate and turn off at the correct time.
An accelerometer, implanted in a jacket sleeve would be connected to the breadboard. When an arm would raise it would turn on the respective LED in the helmet and therefore indicating which direction the user was turning. The final artefact was housed in an Acryic housing to protect it and allow the user to test it easily. The LCD screen also lets the user know which side is illuminated.
SQUASH BALL LAUNCHER A SQUASH BALL LAUNCHER DESIGNED AND MANUFACTURED TO LAUNCH A SQUASH BALL OVER A PREDETERMINED DISTANCE GROUP PROJECT
6 WEEK PROJECT
DESIGN PROPOSAL This design was chosen due to the simplicity and projected performance of the design. It did not utilise springs and could be manufactured at a very low cost. The launch method is latex tubing which is attached to a runner at the top of the main tube which allows for quick and smooth launching. A small launching cup was added during design to hold the ball which is crucial for quick release and reduces movement of the ball inside the tube.
MANUFACTURE
Initial tests of the launcher were not firing as expected from calculations and therefore modifications were made to the launcher to launch at maximum distance.
FINAL ARTEFACT
ABOUT ME
I am a passionate and all-round designer. I enjoy finding out about how products work and how they are made, as well as always thinking of a way to make the product better. I always keep up on the current technologies around the world and am constantly thinking of ways to incorporate these into my designs. Aside form designing, I enjoy participating in sports such as football and athletics as well as being on Loughborough University Athletics Team. This has allowed me to experience working together as a team, and individually. Along with taking part in these activities I also have experience of leading these teams in the form of coaching. EXPERIENCE UXAthon (2017) IBM Design Thinking Workshop (2017) Ruffer LLP Asset Management (2016) Pearson Lloyd Industrial Design (2015) Matthew Lloyd Architects (2014) Fluid Pictures VFX (2014) KP at The De Beauvoir Deli (2011-2015) EDUCATION Currently enroled in 6 month ERASMUS exchange studying Interactive Environment Minor at TU Delft 2:1 in Year 2 of Product Design and Technology course at Loughborough University 3 A Levels; Design and Technology (B), Maths (B), Religious Studies (B) 10 GCSE’s and a Higher Project Qualification (HPQ) PLEASE FEEL FREE TO CONTACT ME
07794940025 charliearelson@gmail.com www.linkedin.com/in/charliearelson
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