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Industrial Design Portfolio

Daniel Stephens


Welcome / Context

Welcome -

Daniel Stephens -

Daniel Stephens Email - Address - 442 Walkden Road, Worsley, Manchester, M28 2NE I am a dynamic, organised, creative student, who is fascinated by design. I love to solve problems, and learn new things. I design products that create a new experience for the user which are both aesthetically pleasing and functional. I enjoy all parts of the design process, from research through to production. I have experience leading teams and presenting in front of audiences

Content 01 / Personal Project 02 / User Experience Design 03 / Design Week 04 / Solidworks - CAD Render 05 / Injection Moulding Tool 06 / Internet of Things



06 03



Duration 05/01/17 - Present

01 / Personal Project


01 -


Personal Project Brief To Learn about the making of a pair of trainers, and use this knowledge to design my own, choosing my own inspiration and style.

Shoes -

01 / Personal Project

Deconstruction I needed to find out how shoes were actually made. When taking apart the shoes I tried different methods, firstly by trying to cut the top half of the bottom half where I found out that the shoes were held together by glue. Instead I used heat to take apart the top from the bottom by placing the shoes in boiling water, the Nike trainer came apart easier whilst the Adidas trainer was more of a challenge due to the threads attaching the upper material to the sole.

‘Insight / The trainers used heat and glue to form the trainer together.’

Construction I needed a last, however as I did not own or have the funds to buy a last, I created my own using blue foam. I then tried to wrap the Flyknit upper round the last however there wasn’t enough material. Instead I decided to use a sock for extra material so the upper could be attached to the sole. Without a sewing machine I used glue to attach the upper with the sock whilst the sock was around the last so it was formed correctly. Once attached I then glued the base of the sock to the sole.

Construction -

Inspiration -

Inspiration -

01 / Personal Project

The inspiration for the project has come from tech fashion. The use of zips buckles and how the product is joined together is on show, this is evident on many Acronym jackets and Nike lab products. Inspiration has also come from the organic shapes of the Hiroshi fujiwara shoes and the space suit.

Materials Research One brand that stands out to me is Stone Island whose material research is very strong, with the company coming out with high end quality materials, not like any other. Their materials have inspired me to use material like there’s in my designs.

Material Research -

The top right image (492Y2) is a poly cover composite which is both opaque and water resistant, this is something which my trainers should incorporated for aesthetics but also function. One of stone islands latests breakthrough material is a nylon metal, this creates a 3D look to the jacket. This can be used with a coating to make it both wind and water resistant. This can be seen in the bottom left 2 images. The middle top image is stone islands multi layer fusion technology, where they laminate a matte polyester to the outside of the coat. All of these Materials can be considered for the shoe, when designing and coming up with the aesthetics of the trainer.

3D Pen Test 01 / Personal Project

I used a 3D pen to draw round the last to form the shape of a shoe and then be able to design the appearance of the shoe in 3D. ABS filament was used as it was stronger then PLA.

3D Pen Test -

‘Insight / 3D drawing easier to visually ideate what the design looks like.’

Exploring Model Making -

‘Insight / Clay is quick and cheap to model ideas for the sole.’ Exploring Model Making -

To further develop the model making stage, clay had been used to develop the forms and see what kind of shape I want the form of the sole to create. The clay was tough and would start to crack on the edges, it turned out to not be a great way to create a form for the shoe. Instead using the 3D pen I created a different sole.

Initial Sketches 01 / Personal Project

Initial Sketches -

Developed Concepts Developed Concepts -

Group / Individual Duration 6/10/17 - 15/12/17

02 / User Experience Design

E 02 -


Smart City Shopping App Brief Your brief is to design a smartphone app that enhances the experience of Smart City living. This app should be based on the group concept development you create and the primary research you do.


User Research 02 / User Experience Design

As a group we found there was a gap in the market for a shopping experience app. To research this further each one of us in the group did our own individual primary research. Research started by firstly putting together a survey which we all used to send to our target market. We then did our own individual research, I firstly started off by interviewing a likely user of an app about shopping. I wanted to find any real problems that have occurred which they could remember, and anything that worked well when planning shopping trip.

User Research -

“I feel as though I’ve left the city not seeing everything it has to offer, I hate missing out.”

The Test -

“The apps and websites out at the moment only show high street brands�

User Research -

I then went into this further by shadowing them on a shopping trip. The whole point in this is to find out the specific pain points, experience goals, and task goals. Also to find out what type of apps users will use to plan a shopping trip, if they do at all. I will also be seeing for myself the true pain points when on a trip.

Data -

Data / persona 02 / User Experience Design

Once our research was completed, we then came together to put all of our data together to start to think about, what specific problem we want the App to solve, and who we want it to be aimed at. We created a site map and also a persona, so we could all use this to create our own user experiences.

Robin Miller Age: 26 Occupation: DJ/Music Producer Home: Highbury, London Type of Person: Interested in Fashion, Frequent Social network user

Persona -

Robin Miller is an up and coming DJ who tours the globe, playing festivals and gigs. When exploring a new city, Robin wants a shopping trip that’s tailored to him. He wants to be informed about exclusive releases and current promotions. Robin wants to visit the best suited shops in a given time frame. Robin wants a stress free shopping experience without wondering around aimlessly. He wants to find clothes he can boast about when he sees his friends back home. He would like to own a rare pair of Nike Air Jordan’s. Robin’s dream is to close the Pyramid Stage at Glastonbury.

Pain Points Lack of Mobile Data. Feeling overwhlemed. Lanugage barriers - signs, directions public transport. Due to time constraints, doesn’t get to visit all intended shops. Shops that are closed or haveshut down. Leaving a city without realising a shop was there that they would’ve loved.

Experience Goals The want a stress free shopping experience without wondering around aimlessly. Want to find clothes they can boast about when seeing their friends back home. Want to improve their social media image by wearing the most desirable clothes.

The User

Task Goals When exploring a new city, the user wants a shopping trip that’s tailored to them. By utilising the city’s optimal method of transport, the user want the most efficient route. They want to visit the best suited shops in a given time frame. The user wants to be informed about exclusive releases and current promotions. They want to minimise the amount of apps/websites they use to find shops of interest.

Technology Use Most frequently use apps including Instagram, WhatDropsNow, Google Maps and CityMapper. Likes to share their experiences in order to promote themselves and gain followers. In their free time likes to browse online stores and fashion blogs in order to keep up to date.

The Concept 02 / User Experience Design

Esta creates a shopping trip tailored to you. It removes the hassle of searching for shops you might be interested in and creates a custom plan suited to your specific needs. Esta will give the user recommendations by collating data from a number of sources, from specific user-defined interests, other Esta user visits and re- views, editors picks and news from popular clothing blogs such as Highsnobiety and Hypebeast. The primary function of the app is trip planning, and therefore Esta will make use of GPS and smart city transport information to generate a shopping route that allows the user to get to the stores they want to visit in the most time efficient means possible. Esta will consider opening/ closing times as well as news on pop-up shops to ensure that the user does not leave a city feeling as though they have missed out on the full shopping experience.

Initial Wireframes These frames are 4 of the chosen 9, they follow the path from entering the home page after setting up your account to planning a trip and pressing go. The app must be easy to use and have the right requirements the user needs to create the specific shopping experience for them.

User Testing The global navigation at the bottom of the screen should be made bolder to make it clear where to navigate. Plan trip should include a rest button if the user changes their mind. The user was also confused which button to press to actually start the trip. As for the map page the ‘end route’ button isn’t needed as the user can press the ‘X’ button in the top right instead. And the circles on the map page are intended to be pressed which wasn’t clear.

User Testing -

“I didn’t know what to press on the pages, its needs to be clearer.”

High Fidelity 02 / User Experience Design

High Fidelity -

Individual Project 6/10/17 - 15/12/17

03 / Solidworks - CAD Render


04 -



Solidworks - CAD Render Brief Using the skills learnt from the CAD module in your first year of university, Use Solidworks and Keyshot to create and render a scooter/balance bike for your own specific user.


03 / Solidworks - CAD Render

The Process -

The process started with mood boards of how the bike will be styled like, and then concept sketches were formed. Specifically looking at frames that aren’t conventional and which are different to any others. The frame is more complex then others as the stem for the seat loops through the back forks. The front forks is also asymmetric to help the child with balance. Once the design had been chosen, I think figured out how it was all going to fit together, and what parts I’m going to need to make the bike functional.

Details -

Exploded View 03 / Solidworks - CAD Render

Balans is a balance bike for kids who are too young to ride a bike, but are very interested in BMX, and want to be able to one day own a BMX for themselves.

I then took to Solidworks to create the bike and once created and assembled, Keyshot was used to bring Balans to life.

The frame is more complex then others as the stem for the seat loops through the back forks. The front forks is also asymmetric to help the child with balance. The frame had been made using surface modelling

The bike has a 360 degree motion. The frame will be made out of aluminium as well as most of the parts on the bike.

Presentation -

Once the design had been chosen, I then figured out how it was all going to fit together, and what parts I’m going to need to make the bike functional.

Individual Project Duration 26/01/18 - 02/02/18

04 / Design Week





Design Week Brief Using a live hinge or hinges you must design home ware product for student accommodation that must be capable of compact storage. The predominant material shall be polypropylene with the exception of fasteners and/or special purpose componentry. The size of the product should not exceed 500mm square and 300mm height.

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Research (Student Accomodation) 04 / Design Week

“My cupboards are tiny! They just don’t fit inside with everything else. ”

Research -

When looking directly in student homes the kitchen is always the problem, It’s messy, dirty and hard to keep clean. I decided to look into this further, and there was a consistent problem students have lots of ‘stuff’ in there cupboards which take up lots of space. One of the major problems were kitchen containers, these took most of the spare space they had. This space could be used for other kitchen accessories which would free up their kitchen work surfaces. I also interviewed the students to see what they thought.

Inspiration I thought that instead of the container being always together it could instead be flat when not being used and could then be stored with the plates, so I looked into origami. Here I used origami books to create generic shapes, and then see how food could be contain inside. When creating the shapes, I would then take away excess pieces of paper which was unnecessary to then form a net. With this net I could develop ideas of keeping the container together.

‘Insight - Origami allows there to be a simple flat design which is folded into a container.’

Prep -

Eat -

04 / Design Week

1. The user will retrieve Hinji, in its flat form, from their cupboard.



1. Th contain remov


2. The user then opens the conta and flattens it, transforming it fro box to a plate. 2. The user will place the food into the centre of the container.


3. Then, the user assembles the food container, by folding the edges, clipping it together and attaching the lid.


4 4. The user can now place their container into their bag for travel.

4. Once the food has been eaten, the container can be reassembled into its box shape and returned to the bag.

Clean -

he user will take the ner from their bag and ve the lid


1. When cleaning Hinji, the user will unfold the container into its flat form for accessibility.


ainer om a

2 3. The food can now be eaten easily.

2. Due to its shape, Hinji can be stored in the plate compartment of a drying rack, reducing the bulk of a standard box container.

4 3

3. When dry, the user can place Hinji in a cupboard in it’s flat form alongside the plates. StoryBoard -

Model / Final Outcome After making origami, three forms were created which were a cup, a pasta pot and a bowl. 04 / Design Week

The pasta pot will be fastened together used air tight clips so that no air would be able to go into the container. These fasteners would be both inside to keep the container together and outside to keep the lid on. The cup will be a pentagonal shape, which will fold and then excess thinner material will then fold into the pockets. To keep the cup up and to ensure it is water tight.

Green Models


Modelling -

Cook, Fold, Eat

Advertisement -


Group Project Duration 20/10/17 - 14/01/18

05 / Injection Moulding Tool





Injection Moulding Project Brief The module explores the design of a small promotional item, together with the means of mass producing that item. This will be done through the process of Injection Moulding and students will be designing and making an injection mould tool to allow the production of the promotional item out of a suitable polymer. As part of this process students will cover design practice, CAD / CAM skills, materials and processes, and group working.

Injection Moulded Porject -

05 / Injection Moulding Tool

Team Work -

The first part of the project began with creating our own individual widget and its mould tool. Once the first stage had been completed we got into teams where we would choose one widget to carry forward to the production side of the module. We decided to take forward a tyre lever for the brand Fox. To begin the process of making the mould tool, we started of by using the cad model to create engineering drawings. We sat down as a team to work out what our roles were and time manage what was needed to be done at certain stages of the process.

Prototyping A 3D printed model was created at the start of the project to ensure that there was no problems with the design, luckily no problems arose from this and we were able to start the modelling phase. Firstly HSM works within Solidworks was completed so that we were able to set up the CNC milling machine. Before creating the final mould blocks out of Aluminium we prototyped the two mould halves out of blue foam to ensure that it was correct.

Prototyping -

05 / Injection Moulding Tool

CAD The final mould halves with the inserts and pins are shown to the right. The two mould halves are now ready to be CNC milled. Four complex inserts will also need to be made, however these will be created using a milling machine, as well as 8 6mm diameter pins using the lathe machine.

Mass Manufacture We also developed our mould tool in order for it to be able to be mass manufactured. Below are the numbers which we worked when making a total of 100,00 widgets.

17.5 70G 13 160 8 3,001,202 52.5 ÂŁ19,950

Mass per widget Mass per mould Weeks Hour weeks Hour maintenance Tonnes of HDPE Units every 13 weeks Estimates ÂŁ380 per tonne

Manufacture 05 / Injection Moulding Tool

Throughout the process of manufacturing the mould tool, creating the inserts was the most hands on part of the project. This was where we were able to use the milling machine, the pillar drill. Before Injecting we had to create the metal insert which was manufactured by the water jet cutter, and then finished off using a hand saw and file. Once all of the parts had been created we were able to set up the injection moulding machine ready to inject the widget.


Milling machine

Injection Moulding Manufacture -

Final Outcome -


Duration 07/02/18 - Present

06 / Internet of Things -



Internet of Things Brief Identify an opportunity for an IoT product for which the industrial design and app interface are dedicated to a clearly defined context e.g. healthcare, leisure, sport, security, travel. This opportunity may be based around current needs or projected up to five years into the future.



06 / Internet of Things -

Problem / Idea -

People take distance running very seriously, and strive to run faster and quicker. However these runners have no help to achieve this, they don’t know their form, they don’t know how fast they should be running at certain paces, they don’t have a personal trainer to guide them in the right way. The drone will: - guide the users on where they should be running, - Track their form to look at their stride, arm and head movement. - Push them to run their runs faster each time, to reduce their time.

Form Board / Inspiration -

Form board -

I started looking into simplistic forward flowing shapes, which will offer direction for the design of the drone, however including harsh champhers and intersting split lines to add important detail. Then I looked into the design from the brands the runners wear, like nike and others. These brands offer bold colours and use geometric patterns, whilst keeping a fluid form to offer direction and speed.

Sketch Developement -

Initial Sketches -

06 / Internet of Things -

Low Fidelity Modelling Modelling worked in direct correlation with the ideation sketches and development. I would sketchthe ideas out and then make a quick mockup out of blue foam. This made it easier to visualize what the design was like. This helped to change my design from being very flat and geometric to have more direction and curvature.

Low Fidelity Modelling -

Current Project - In the developement phase of the project

About / Thank you

About Work Experience Uxathon November 25 2017

Winners of best Concept. Intense one day live brief, involving international communication with our clients working together as a team to create a user experience

Apple Specialist June - October 2017

Being a specialist meant educating and enriching the life of the customer. Working as a team to adapt to change, overcome problems, and create excitement around the store

Worsley Old Hall Kitchen Assistant April 15 - April 2016

Working under timed constraints as a team, maximising efficiency. An eye for detail was important to maintain cleanliness and order.

Education Loughborough University 2016 - 2020

BA Industrial Design and Technology (2:1 First Year)

Canon Slade Sixth Form 2014 - 2016

Art and Design (A), 3D Design (B), Physical Education (B)

Thank you Daniel Stephens Email - Address - 442 Walkden Road, Worsley, Manchester, M28 2NE

Industrial Design Portfolio  
Industrial Design Portfolio