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Daniel C opley Design Portfolio Product Design Engineer


Sketching Skills Ability to use fine-liners, pencils and pens to present a range of ideas and to communicate form.

Design Project: Various sketching exercises

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Below is a collection of sketches and renders that I have produced. They were drawn as part of an exercise to experiment with different shapes and forms. My preferred way of communicating ideas and concepts is to sketch them so I am able to produce rapid sketches when I need to make a quick point. Many of the drawings below were produced within 2 mins. When time permits I can produce much more detailed and accurate drawings and these examples are also shown below.

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“A picture is worth a thousand words�


Presentation Sketching Sketches produced to a high quality and rendered with pens then with PC software Adobe Photoshop.

Design Project: Sketching exercise

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When presenting work to a client I produce the best sketches I can. I spend a lot more time on presentation sketches than on regular concept sketches. When the outline sketch is complete I uses rendering pens followed by photo-editing software, Adobe Photoshop CS5. I have used Photoshop extensively for many years and am able to use most of its features to great effect. The products below are samples of existing products on the market where I have sketched them to their finest details as an exercise to communicate a products form.

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Design Project: Sketching exercise


Snowbell Snowball Maker A design project introduced by M&S with the brief to design a stocking filler for the Christmas season.

This is an example of Presentation Sketching with a real client using my own design. It is also an example of rapid idea conception as this design project was completed in just 1 week. A description of the product is shown in the poster. Both the product and the background were sketched with fine-liners, rendered with Adobe Photoshop, and pieced together with text in Adobe Illustrator.

Concepts for Marks & Spencer

Concept Title Snowbell Snowball Maker A child’s winter toy - a hollow sphere in the shape an Max 30 word aspirational concept description goesofhere. animal is used to compress snow into a snowball. Approx which 14pt but can be your choice of typeface and colour Ideal for young children who cannot make snowballs.

Fill

Crush

Play! Š Daniel Copley & Brunel Design October 2012

Design Project: Stocking filler (for M&S)

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To present a photorealistic concept of a product I incorporate graphics software to create a photomontage. The software I use for this are Adobe Photoshop, Adobe Illustrator, and Adobe InDesign. I used Photoshop to edit exist images and to piece them together whilst I used Illustrator to compile the poster and InDesign to add custom text and captions.

Graphic Communication Use of graphics software to produce quality eye-catching and effective posters to communicate a product.

Panasonic POTESTAS

presents the all new

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t

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Media orientated hardware buttons and 16:9 widescreen LCD display Universal remote to many other Panasonic devices 8.1 megapixel camera with Lumix technology Viera Connect integrated

Developed by:

Evensis Design Engineers 7

Design Project: Graphic communication - Smartphone by Panasonic


Anchorline Flood Aid James Dyson Foundation “Future Solutions� design proposal for a product that aids people during floods in the UK.

Wireless transmitter/receiver - sends an alert to emergency services when any glass is broken so that they know people have anchored themselves. Handle - used to hold onto during a flood.

Primary Line (output) - with thicker and longer rope than a Personal Tether, this line is used to connect with another Anchorline unit. Glass cover to break before use. Primary Line (input) - this is where a Primary Line from another Anchorline unit connects

A device that is attached to street lights and connect with each other in times of flooding to create a safety line for people to use to move through flowing water. It also has 8 personal tethering lines to anchor someone so they are not swept away.

Wirelessly controlled LED - lights up as red, amber, or green to indicate flood risk level.

Personal Tethers - 4 on each side, they consist of a 5m long rope with a carabiner on the end to clip onto a person/object to stop them being swept away in a flood.

Glass panel - break to access Personal Tethers.

Clamps - these grip onto a street light when the leaver is pulled down on each side. A padlock can be used to lock it and avoid tampering.

Before a flood

During a flood

After a flood

The units are placed on street lights and telegraph poles down a main street of a town that is likely to become flooded. The LED on the top of the unit will indicate the flood risk level. To avoid unnecessary use or vandalism glass panels and cases cover the tethers.

People can use the Personal Tethers to anchor themselves or objects so that they are not swept away. The Primary Line can be connected to any other unit to provide a secure line to move through flowing water. The emergency services are notified if any of the glass is broken and tethers used.

Once the water is no longer flowing fast, the Personal Tethers can be used to securing floating craft like evacuation boats. The units’ Primary Line can also be used in extremely icy and snowy conditions as a way to keep people on there feet when the ground is too treacherous to walk on.

Design Project: Anchorline Flood Aid

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The brief was to design a product that could provide aid in any chosen extreme weather environment in the UK and could be implemented withing 10 years. There was just 1 week to produce a design proposal. Anchorline is a device that is attached to street lights and connect with each other in times of flooding to create a safety line for people to use to move through flowing water. It also has 8 personal tethering lines to anchor someone so they are not swept away. 188 concepts were presented to the clients and this design was selected as one of the Top 16.

The

My

Problem Solution Objective: To design a device that attaches to street lights to assist people during floods

What is present nearly everywhere in the UK, firmly grounded, always visible and available during a flood that can be used to support people before, during and after a flood? The answer:

Street Lights

Flooding Once water levels reach 6 inches deep then it is virtually impossible to walk through it. This can leave people

stranded The facts:

- 6 inches of fast-flowing water can knock over an adult. - 2 feet of fast-flowing water can move a car

If you’re outside and caught in a flash flood where do you go?

What if you’re out of the house? The Environment Agency UK does not have anything on this issue but the general advice is this:

There is no guarantee that someone will answer the door if you knock and public buildings are not always in the immediate area

Concepting for a solution began with jotting down thoughts that came to mind, small notes which then developed into quick sketches. Above are the beginning pages of my design process. Each sketch becoming more detailed as solutions were found.

My solution would need to focus on three things: - How to attach to a street light - The tethering system - Storage of rope through coils and body shape

Avoid moving water and find higher ground To avoid being swept away by the flood water you

need to hold onto something firm

Many people have been killed or injured because they have been taken by flowing water. A flood can last a long time and

your strength may fade,

resulting in you being swept away because you cannot anchor yourself.

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Note that the clip design that I have chosen to use is a carabiner. Before the design of the clip I looked back a an original sketch which showed carabiners as the clips. This was because it was the first to come to

mind as it is the most common and reliable form of clip so why design a new one? The next product concepts were more focused and detailed.

Design Project: Anchorline Flood Aid


Brief: To design a promotional product specifically for mass production.

Ergonomic Bottle Opener Sketches

Design Project: Ergonomic Bottle Opener

Having firstly done research into promotional products I decided to design a unique bottle opener. I took inspiration from a couple holding hands and used this to sketch concepts of a bottle opener that could wrap around a hand in the same way as another hand would.

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Having experimented with the concept I produced a more accurate and detailed drawing of my idea which I digitally rendered with Photoshop to give it a more 3-Dimensional look to communicate the form better. After this stage, the concept was compared with others produced by the group members and chosen to be the design to be continued to manufacture.

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Computer Rendered Sketches

Design Project: Ergonomic Bottle Opener


GA and Component Drawings

ITEM NO.

76

5 1

PART NUMBER

Material

QTY.

1

Glove

Polypropylene (PP)

1

2

Bottle opener attachment

Stainless Steel (SS)

1

3

Ring

Polypropylene (PP)

1

4

Lens

Clear acrylic

1

5

Bottle opener mechanism

Stainless Steel (SS)

1

6

Rivet

7

Logo (under Lens)

1

Aluminium

2

Paper

1

5

5

114

48

6

2 3

6 54

41 UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH: TOLERANCES: LINEAR: +/- 0.5 ANGULAR: +/- 0.2

4 1

NAME DRAWN CHK'D APPV'D

Daniel Copley

Note: This drawing shows a left-handed bottle opener. Right-handed bottle openers can be made by changing a few manufacturing processes. See maunufacturing instructions for details.

SIGNATURE

DATE 20/12/12

DEBUR AND BREAK SHARP EDGES

All outer edges of the glove are rounded by 1mm

GENERAL ARRANGEMENT DRAWING

Group 20 TITLE:

Ergonomic Bottle Opener

MFG Q.A

Institute:

SCALE:1:1

Design Project: Ergonomic Bottle Opener

A3

Brunel University SHEET 1 OF 1

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In order to fit perfectly the product dimensions were based on anthropometric data sourced from the book ‘The Measure of Man and Woman’. With these very specific dimensions in mind I constructed a CAD model of the product in Solidworks and from that made a series of component drawings and a GA drawing. I make a great effort to produce accurate and efficient technical drawings. These drawings have been handed over to a team to manufacture and they have not had to ask for confirmation of any dimensions or forms.

11.8

11.8 11.7

R 1 .3

R1

.3

R10.8

3

R1 1.9

.6 07 R1

3

48.8

50.8

53.8

R1.3

3

50

2

159.2

2

26

R1

6

24

3

2.5

2.5

R 24

.6

15

3

34.5

0.3

1

3

80.7

3

UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH: TOLERANCES: LINEAR: +/- 0.5 ANGULAR: +/- 1.0 NAME

47.5

33

39.1

19.4

DRAWN

Daniel Copley

DEBUR AND BREAK SHARP EDGES

FINISH: Polish

SIGNATURE

DATE

Round off all outer edges by 1mm radius

TITLE:

Glove

20/12/12

CHK'D APPV'D

153.3

MFG Q.A

MATERIAL:

Institute:

Polypropylene (PP) (any colour)

GROUP 20

13

COMPONENT DRAWING

Brunel University

SCALE:1:1

A3

SHEET 1 OF 1

Design Project: Ergonomic Bottle Opener


Computer Aided Design (CAD)

Design Project: Ergonomic Bottle Opener

Below are various views of the final rendered CAD model of the bottle opener. It was constructed and assembled in Solidworks with individual components then rendered with Photoview 360. I am also experienced with SketchUp, another piece of CAD software. Examples of my work with this software are shown further into my portfolio.

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The product would be subject to a force to open a bottle. To test and confirm which materials would provide the right properties and not break due to this force I use mechanical stress analysis software. The software that I currently use is ANSYS. The images below show visually the shear stress the product would experience. The product is currently being manufactured.

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Mechanical Analysis

Design Project: Ergonomic Bottle Opener


Brief: To design an LED luminaire for fashion retail stores. Client: Philips and LET

Architectural Luminaire Sketches

Design Project: Architectural Luminaire

There were many pages of concept sketches and a sample page is shown below. This page specifically shows my ability to sketch more technical mechanical ideas as well as form sketching.

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This page shows a collection of some of the modelling and prototyping that I completed for this project. The top three images show two 2.5-Dimensional models of how the lens would rotate and how light would be manipulated and one image to show the basic form of the lens and its movement. The main image shows a “works like, looks like� model. The model is functional but also formed to scale.

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Modelling and Prototyping

Design Project: Architectural Luminaire


Once again a GA drawing was produced. This one was purely to communicate the scale and form of the final design of the product. The luminaire is far more technical than the Ergonomic Bottle Opener so I included this drawing to show that I am able to communicate more technical products though use of detailed section cuts and cross sections.

GA Drawing

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Item No.

Quantity

1

x1

2

x1

3

x1

4

Description

Quantity

LED Unit

8

x1

Reflector

Sphere cradle

9

x1

Cradle attachment

Metal grip ring

10

x1

Anchor/attachment

x1

Inner hemisphere

11

x1

Heat sink

Description

14

5

x1

Luminescent lense

12

x2

Long bolt

6

x1

Outer hemisphere

13

x1

Outer ring

7

x1

Dispersion lense

14

x3

Short bolt

15

x2

Attachment nut

16

x2

Anchor nut

17

x1

Fresnel lense

71 16

B 10

1

Item No.

11

3

5

1

9

6

2

7

15

12

80

4

DETAIL A SCALE 1 : 1

A

16 B 13

160

160

57 SECTION B-B

8 UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH: TOLERANCES: LINEAR: +/-0.5mm ANGULAR: +/-0.2mm

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NAME

17

DRAWN

DEBUR AND BREAK SHARP EDGES

FINISH:

SIGNATURE

DATE

DRAWING NOT SCALED

TITLE:

Daniel Copley

Spherispot

CHK'D APPV'D

13

MFG Q.A

MATERIALS: White Acrylic Chrome Stainless steel Brushed Stainless Steel WEIGHT: N/A

Design Project: Architectural Luminaire

TOTAL COMPONENTS: 17

INSTITUTION:

SCALE:1:2

Brunel Unviversity

A3

SHEET 1 OF 1

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Because the LED lighting unit was given to me the whole design had to be based around that. The CAD models below were constructed around a pre-made CAD model of the unit. The model was given material properties and was assembled with the other components that I designed. The image in the top right was produced in Adobe Photoshop and shows how the product would look in a scenario. In this case a fashion retail store.

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Computer Aided Design (CAD)

Design Project: Architectural Luminaire


Brief: To design an a kitchenware product following guidelines and specifications laid out by a brand.

Vive Wine Jug Sketches

Design Project: Vive Wine Jug

For this brief I designed a Wine Jug. It is not a decanter as that is used for older wines that need the sediment removing. The jug is used at social events as a classier way to serve wine than the wine bottle where its primary functions are to store, transport, and measure wine and not to pour.

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To assist with the design of the wine jug, 3D models were produced to get a better feel of the product and provide different perspectives that 2D work (sketching) cannot show. Below is a high-density foam model of the wine jug design. It is partially functional as there is a hole cut into the body to fill with water so that the spout can be used. The spout is a nondrip design. Also, the handle is to scale so that is functional.

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Modelling and Prototyping

Design Project: Vive Wine Jug


CAD Modelling

Design Project: Vive Wine Jug

These CAD images are of a model completed in Solidworks 2012 and rendered in Keyshot. As well as solid modelling I am able to surface model as shown here. I can also convert surface models to solid models for the benefit of mechanical analysis as shown on the next page.

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This is my latest mechanical stress analysis work using ANSYS. It focuses on the handle of the wine jug and it calculates the stress intensity in the object to see whether or not it will plastically deform or even fail. The force used on the end of the handle (where it attaches to the body) is the weight of the product (calculated in Solidworks) plus the weight of 75cl of wine. From this I was able to determine the material and shape of the handle.

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Mechanical Analysis

Design Project: Vive Wine Jug


Migrant Worker Homes A project developed with client The Building Trust International to design homes for migrant workers in Singapore.

Design Project: Migrant Worker Homes

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The brief was to design homes that could accommodate 8 migrant workers in Singapore because the country has a lot of illegal homes that are both dangerous and unhealthy. These homes, therefore, had to be inexpensive, provide all the necessary living conditions and not impose upon the Singapore landscape. The project was undertaken in a group of six where the tasks were distributed based on the strengths of each member. One of my best strengths is in Computer Aided Design so one of my tasks was to compile the final CAD models of the design. To broaden my range of skills I also undertook the organisation of research

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for the project as that was the area of design I had not focused on in previous group projects. The CAD model was produced using Google SketchUp (now known as just SketchUp but owned by Trimble). I first started to learn how to use the software many years ago from scratch and I am now very comfortable using it to produce accurate and realistic CAD models. To render the model photorealistically I used Kerkythea 2008. The final model of the migrant worker home is shown below.

Design Project: Migrant Worker Homes


Architecture Addition interest in the design of buildings for which I produced sketches and CAD models.

Below is a collection of sketches and CAD models. The CAD models are 3D representations of my house. I used Google SketchUp to produce them as I know that it is one of the preferred pieces of software used for architectural design. The sketches are from a Fine Art project. They are primarily drawn with black ink pens which have been rendered by using a wet paintbrush it wash the blank ink across the drawings. The coloured sketches were done using watercolour paints.

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Sometimes a product wil be subject to multiple forces and choosing the right material and shape requires the use of mechanical stress analysis software. I am able to use software called ANSYS to a good ability and have used it in projects such as the one below.

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Photography A personal hobby which I like to incorporate into my design projects whenever I can.


Detailed Drawing and Rendering If I get any spare time I enjoy spending it by producing more detailed drawings of something that interests me.

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Design seems to require a lot of quick concept sketching and so I don’t get the chance to spend a long amount of time on more detailed drawing. Therefore, in my spare time I like to casually draw anything that interests me at the time. The ones bellow are of game characters and they took several hours each to complete. The more I draw, the better I become and this is reflected in my concept sketching.

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Thank you for reviewing my design portfolio.


Portfolio of Work - Daniel Copley