Product Design Engineering Portfolio 2017

Jasper Mallinson CV and Portfolio 2017

“

Brunel University Product Design Engineering (BSc) undergraduate with experience in commercial engineering, design studios and other creative industries. A history of keeping positive and working efficiently under pressure in both professional and academic situations. Always actively learning new skills in and outside of curriculum, I have become proficient in numerous software packages, metal machining, tig and mig welding, circuitry skills and varied design and ideation techniques. I’m a practical person who has tinkered, designed and created since a child, resulting in an internet following at an unusually young age which lead me to also develop a range of capitalised media and advertisement skills.

EXPERIENCE Heatherwick Studios

[Work experience placement]

06/2013 - 1 week

As one of two selected placement students, I developed multidisciplinary skills in both team and solo design for major commercial commissions. Worked with concept generation and development teams, work consisting of ideation, card/foam modelling, research, admin and presentations to clients for future projects.

Packham Engineering

[Steel fabricator/ installation work]

10/2014 - 02/2015

Worked in an intimate team of 4, refurbishing and improving product manufacture lines for Ryvita and Yeo Valley. Was a major team player in the design and making of bespoke components for large-scale pieces of machinery used in mass production. I often drove large distances around the south west where I worked with clients to resolve problems.

Structure Workshop

[Work experience placement]

The Woodland Workshop

[Woodworker/ designer/ film-maker]

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07/2013 - present

Gained experience in customer service and monitoring glamping units. Was also involved in the design of portable parachute shelters and proposed a circular gravity tensioned concept that was used for the final design at Glastonbury Festival. Developed team skills working with ten craftsmen and traditional green woodworkers for two months building a RIBA shortlisted luxury treehouse. I had to time manage my work as I was also commissioned to film and document the process. I produced four films catered to different social media sectors employing After Effects, Animate, Photoshop and Final Cut Pro. The Facebook video gained over 250000 hits, boosting company revenue.

Hive Beach/ Watchouse

[Waiter/KP],

08/2014 - 10/2014

Worked at the award winning seaside restaurant and cafe in Dorset, where I gained experience in the customer relation side of buisinesses.

04/2013 - 1 week

Spent a week at a London based structural design agency where I was asked to use my Solidworks skills to model a complex tetra-helix sculpture for artist Conrad Shawcross, my model subsequently being used for the installations proposal at Kings Cross. Working as part of a small team and juggling multiple commissions, I gained valuable experience in the office environment.

Volunteered to work building a school in Cambodia. I was asked early on to build a workspace for local builders and later worked as a team building and forming concrete foundations/structures for new loos.

Action Workshop

Ski Esprit

[Creator/ Frontman]

03/2012 - 10/2013

Founded a small business doing parties and activity days for children comprising of working with groups as a team to discuss and draw up a storyline before themselves taking on the roles within their film, edited using Adobe After Effects and Final Cut Pro X.

Treak Community School

[Volunteer]

[Chalet host]

06/2015 - 2 weeks

02/2015 - 04/2015

Drove to France and secured work in a competitive climate as a chalet host where I had to use my initiative to learn everything on the job. I developed strong intuition and enthusiasm under intense pressure and long hours.

EDUCATION Perrot Hill

2005 - 2009

• DT Scholar • Led construction project to raise money for Cancer Research • Success in two external design competitions, winning funding for school

Bryanston School

2009 - 2014

• DT Scholar • Raised £3000 for construction of skatepark and led student team to build it • Cross-country athlete of the year • Awarded Bronze Crest Science award for Toyota eco car Challenge

Brunel University London

GCSE

shop for projects out of university hours along with a group of others.

• Distinct recognition and praise of two university design projects from external companies.

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3D Art

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Maths

Physics

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Physics

Maths

2015 - present

• Active and socially minded community member - designing and building a communal work-

AS

YEAR 1 Overall Equivalent to a

Electronics/Mathematics Mechanics For Design

1st

YEAR 2 from modules including:

Materials and Manufacture Design Process Graphic Communication

Current modules include :

Electronics/Programming

Design for Manufacture

Design Process 2

Design Communication

Mechanics and Stress Analysis

• Constantly developing diverse projects alongside university.

SKILLS AND INTERESTS • Very visually minded, creating endless ideas and models since a child.

• Self-motivated and enterprising individual, securing future work alongside uni as a monthly presenter and inventor on a upcoming Syncoms Youtube channel.

• Proficient in numerous design related software (displayed on previous page).

• I enjoy travel and seeing new things. I was recently lucky enough to climb the highest mountain in Indochina and was part of a duo • Skilled tig and mig welder with highly developed metal fabrication who drove (and frequently repaired) a tuk-tuk across the width of and metal machining abilities.

Laos.

• Passionate about technology and more inspiring ways of fulfilling • I enjoy skateboarding, particularly the creativity it encourages in briefs with experience in heavily R&D orientated projects such as general and in skatepark design. wireless lighting and quad-copter design.

• I like film and music, having done lots of editing work in the past • Full and clean UK drivers license. and performing to 500+ people in bands a few years back.

Part 2: Selec

Part 1: Intro and Bio

C O N T e n t s -

(5 - 9)

3D Printed Biodigestors (25 - 27)

Garden Twining Aid (17 - 19)

Robotic Tea Coaster (33)

Welcome This folio is arranged into a two page bio followed by selected project pages then demonstrations of other key skills. Thanks for taking the time to view.

cted Projects

Part 3: Showcase of Other Skills Wireless Lighting (29 - 31)

(39 - 47) Guitarpick For Disability (35)

All Terrain Landing Drone (13 - 15)

Precision Luminaire (21 - 23)

Laptop “Legs” (37)

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Part 1: Intro and Bio

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B a c k g r o u n d -

I liked having A Lot of projects as a child

Unusual interests

The house was always a melting pot of ideas. My brothers, friends and I constantly building and inventing on a daily basis. We made bungee swings, a summer sledging park, fireworks, boats, (tried an aeroplane..) and much more. At 11 I started one of my first major solo projects - A working rollercoaster.

Big projects

I made a 50ft rollercoaster from old rollerblades and scrap wood, gaining over 170 000 views on Youtube (https://www.youtube.com/ watch?v=XTJxPpPCmFc&t=3s). Other big childhood projects included building a 20ft trebuchet from local trees for a school medieval day, learning various green woodworking techniques from my dad.

Competition success

I started designing for competitions at the age of 10, designing a ride which won a large themepark design challenge. At 11, I led a team in a competition to design the 2012 velopark architecture and layout using Cad, sketching and modelling. We were invited to London as one of four finalists where we were the youngest team by five years.

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B a c k g r o u n d -

I Enjoyed Making unusual things.

Maturing design processes

I refined a gravity tensioned sustainable parachute shelter design and created more extensive models of ideas, helping me succeed in more complex final prototypes like the snowshoe concepts on previous page. At 16, I explored more manufacture and commercially orientated inventions like a simple modular record hanging system.

Inspired technical direction

I became more inspired by products where solid scientific foundations allow more progressive and exciting opportunity. I made a short film on MR fluids, did a large project creating a comprehensive guide on magnetism and magnetic effects within materials and created a working wireless power transfer rig.

Expanding skill-sets

I had well developed general fabrication skills, building skateparks, a small pavilion and even a workshop with friends when I arrived at Uni. I Secured a week at Heatherwick studios, working on major architectural projects, worked at “Structure Workshop� in London building a tetrahelix sculpture in Solidworks for a major commission and worked 3 months as an engineering contractor.

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Part 2: SELECTED PROJECTS

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M G D R O N E

The All Terrain Landing Quadcoptor A Group Project In Quadcopter Design For Manufacture

Ability to take off from rough terrain and sloped surfaces up to 30°

Independent lifting of legs after take off to defined horizontal position via single motor and unique mechanism

Lidar detects ground during landing. This also allows precise height feedback to motor controller, resulting in more accurate vertical position locking

Internal mechanism drops legs while drone holds its position. The legs naturally orientate themselves to the grounds geometry via gravity

During flight, horizontal legs allow for full 360° uninterrupted views for any additional camera gear

The same universal leg lifting and dropping mechanism then locks the legs in position. With the drone now stable, the rotors automatically cut out 13

Designing a Safer Way to land quadcopters without compromising performance An unresolved, relevant design issue

Contact with drone rotors can cause severe injuries ranging from lacerations to broken bones. These injuries are often the result of people trying to catch the drones as existing systems restrict location options for landing due to unsuitable terrains. As the drone market grows so do injuries, with propeller guards not adequately addressing this issue. We saw the need for a simple, cheap and safe landing system, adaptable across the drone market.

Team design process and an elegant solution

As a group of six, we designated, timetabled and used cloud based systems to successfully integrate all team and individual work. My focus was on the landing mechanism, the final solution consisting of an injection moulded cam system that operated the movement and locking of all legs through a single motor. This drastically cut weight, complexity and cost relative to alternatives like controlling individual legs with multiple motors and sensors.

A focus on design for manufacture

Material suppliers were researched and compared. Nylon 66 GF30% was eventually chosen for plastic components within the landing mechanism. My parts could keep a low friction coefficient while retaining high impact resistance, toughness and strength. This material was analysed with my parts in FEA software to further argue this material choice. 2 degree draft angles were added to all parts and injection port / ejector pin placements integrated into the design.

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The Pocket Sized Garden Twining Aid

G R O N W 1

A Industry project to design a new hand tool for garden care

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Finding a garden job where demographics are excluded as a result of existing methods and products.

Group research and sub-brand development

Part of the task was as a group of 6, to develop and justify a company sub-brand. Our company “GRON� was concerned with marrying trusted forms and colour palettes with innovation and less mainstream problem solving to create original, inclusive products detached from age groups and demographics that were too specific. To define the brand we developed slogans, a visual code, brand specifications and an overall ethos

A divergent development process

After identifying garden twining to be an everyday task that many groups of people struggle with for different reasons, I began to develop solutions. After initial ideation, four designs were modelled. A modular testing kit was employed on a potential user to quantify the easiest hand manoeuvres for such a product.

This along with feedback from the parent company eventually was able to justify a specific direction.

A proven, tested and fefined solution

The pivot point served the duel purpose of also cutting the wire, allowing a very large mechanical advantage. A rubber cone guided wire into these teeth and also acted as a spring. This cone was tested in the simulation software ANSYS to ensure correct thickness/material choice. The shell (made in Solidworks) was designed alongside injection moulding design rules with uniform thickness, draft angles and reinforcement chamfers.

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H E N L I E N -

The First True Precision Track Lighting System Selected - chosen by Mike Stoane lighting as one of four final designs from 130 submitted projects.

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New Ways to Light Spaces Translated Through Form Broad technical R&D

Airflow paths for heat routing were designed to be uninterrupted for all luminaire orientations and the body itself would be made from anodised aluminium to improve thermal conduction. The main body was given rotational symmetry to an extent, allowing it to be CNC turned then post-processed with other low unit production manufacture techniques.

A unique focus

The main focus of the design was to create luminaires that could be set to precise orientations. This was necessary as lighting in retail environments is often intended to create symmetry, repetition and other effects. Displays are often set up by uninformed, unskilled workers so the desirable effect either takes hours of tinkering to achieve or is unfulfilled entirely.

A functioning prototype

The body was turned from PU material before cooling slits were milled and the whole thing was carefully cut at a 45 degree angle. Both dials were turned on a lathe before locating slots were milled and decals added so orientation could be accurately read off the finished model. A Xicato LED module, reflector and transformer were all integrated to create the working prototype.

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Canon RSO: The Bedless, Housingless, Portable Extruder A week long project re-thinking the manufacture of remote and tailor-able biotanks for Canon’s “Sustainable vision of 3D printing” challenge.

r s o

Variable printing radius via different sized poles

Quick, delocalised design desicions can be made

Bypass design for manufacture/manufacture costs

System spirals up so height only limited by stability

Can print in locally sourced recycled materials

Can print meshes to encourage nesting of bacteria 25

Arborloos

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Anaerobic biolatrines

Dry-compost Latrines

Aerobic biolatrines

Pour-flush toilets

Rethinking Future applications of 3d Printers Research into a big real world issue

Some of the more notable findings looking into the largely under-met UN millenium goal 10prt2 were; i) funding towards separating humans from excreta is irrationally low due to its intrinsic ‘taboo’ ii) 4000 children die a day from diarrhoea (usually related to contact with excreta) iii) in India alone 560 000 practice open deification. iv) solutions vary hugely and often (as with the recent funding in India) are ineffective.

Success driven design

Varying conditions require varying methods of treating waste however this can almost always be done passively with chambers and screens. I quickly found that a singular umbrella design is impractical so set a brief to take inspiration from current successful solutions and design a production system that could cut design for manufacture costs, material cost and transport costs to remote areas with more specialised needs.

An unorthodox solution

The final design consisted of five ‘arms’ connected to a central body. On one arm’s end there was an extruder. The machine rotates and extrudes a spiral, building its own structure to work from unlike most other 3D printers so the whole system is much more compact. A print head then moves back and forth on one arm inside the boundary, extruding low precision (1cm layer thickness) but complex reservoirs and networks allowing the construction of many different biodigester types.

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N O D E -

The Personalisable Wireless Lighting System A project investigating future concepts of user-centred flexible lighting

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new possibilities through New Materials

An ambitious brief

The initial brief I set myself was to design a lighting concept that would give any unskilled user the tools to design, build and rearrange home lighting without any external knowledge or input. I was able to seek advice from two reputable members of the lighting design community; installation designer Bruce Munro and Atrium design engineer Iyassu Yohannes.

A range of solutions

Wanting to make the design more intuitive and flexible, I started experimenting with less conventional methods of achieving the various fundamentals of a luminaire. I created a prototype using wireless power transfer via inductive coupling, a model that distorted a membrane below a small reservoir of water into lenses and finally a model using tinfoil as a substitute for conductive fabrics.

A fully functioning proof of concept

The final design firstly comprised of a “wallpaper” (iron filing impregnated sheet), an insulating layer of polyethylene and a top layer of nickel/ copper conductive fabric. This was to be made in modular sheets that velcro’d together. Lighting units magnetically stuck anywhere on the wallpaper with ‘needles’ piercing between the top conductive mesh to the bottom iron section.

Users could “pick off ” and rearrange lights to whatever arrangements they wanted.

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B r e w t o y o u -

The Line Following Tea Coaster A small project into the use of mosfets and transistors as logic gates to control motors

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Theory and practical skills I did alot of out of class research deeper into the workings of mosfets, transistors and logic gates. I wanted to use the technology in a quirky way to design the most over-engineered tea coaster I could - able to track and follow any black line (done with a combination of IR detectors , a power breakout and an integrated motor controller circuit). I wanted to show off the electronic workings through its aesthetics which I did by tig welding a stainless frame and creating a sort of ‘pcb facade’ on the outside.

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F I X P E R T S

A Guitar Pick For Someone Who Could Not Grip A group project designing a guitar pick to be used by a friend born with a disformed hand

Finding Solutions For The 1% Fixperts is a project to encourage “fixing� problems that may be too specific to be addressed by larger companies.Our client: John played guitar but due to a birth deformation had to selotape a pick to his hand to play. Our solution was as functional and simple as possible. A 3d-printed body held a rubber strap which served a duel function of securing to the thumb base and locking down the pick against the body. We filmed the whole process which I then edited (https://vimeo.com/159006403), the film becoming featured on the Fixperts company front webpage.

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The Legs That Stand High Above Desk Clutter A personal design project for a potential future commercial product

P O S E R -

Extra-Curriculum Problem Solving

Better Through Simplicity

When short of desk-space during revision and still wanting to play laptop music, I started looking into laptop stands. I found that all laptop stands on the market (even the really successful ones) succeed in improving posture by raising the screen and improve ventilation but barely reduce desk space usage at all, even though many claim this as a major selling point. I decided to try to design for this unsolved area, allowing me to try my hand at a more simplistic and aesthetically driven product.

I realised that a laptop stand could effectively ‘pin’ itself against a wall as shown above by dropping a small straight section in the gap between a desk and a wall (gap of 2.5 - 12cm).

A quick prototype worked perfectly (I still use it today) and several iterations later I have a final design I’m happy with. It is simplistic and aesthetically connects with users by mirroring humanistic poses in different positions, it uses much less desk space than competitors and can be made for a fraction of the price.

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A Project in Simplistic Problem Solving I realised that a laptop stand could effectively ‘pin’ itself against a wall as shown below by dropping a small straight section in the gap between a desk and a wall (gap of 2.5 12cm). A quick prototype worked perfectly (I still use it today) and several iterations later I have a final design. It is simplistic and aesthetically connects with users by mirroring humanistic poses in different positions, it uses 1/3 of the desk space as a laptop, much less than competitor stands and can be made for a fraction of the price.

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Part 3: SHOWCASE OF OTHER SKILLS

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I d e a t i o n -

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Jasper Mallinson Product Design Engineering