Page 1

Jonathon Stelling Product Design Engineer

2018 w w

The College of New Jersey, 2015

ABOUT ME Innovative, logical and a dedicated engineer. With extensive knowledge gained from working across the engineering field and experience operating in teams from a wide range of international cultures, through studying in the UK and the US, I am currently seeking a graduate position in design engineering.

3rd July 1994 British York, UK

2 +447527351353


Northumbria University, Newcastle, UK Product Design Engineering BSc (First Class Honours) 2013 - 2017

The College of New Jersey, Ewing, New Jersey, US Computing, Business, Digital Media and Web Design 2015 – 2016

York College, York, UK Engineering, Manufacturing Engineering and Performing Engineering Operations 2010 - 2013

Work Experience

The IRNV Group, York, UK Lead Product Developer Since August 2017

Flankware, Newcastle, UK Design Engineer 2013 - 2017

ESG, Leeds, UK Design Engineer Intern Summer 2016

Skills ECAD & MCAD SolidWorks / TurboCAD / Maya / Keyshot / EAGLE CAD Programming & Electronics -BASIC / C / C++ / Javascript / Python / PHP -Arduino / PICAXE / Processing / Particle / Brackets -PCB Design Manufacturing 3D Printing / Machining / Tool Work / Boxford CNC Other Microsoft Office / Adobe Creative Suite CES Edupack / HTML / CSS


Ch il l M edia I nnovatio ns.


N ite site & N o c t ur na .


___ Foot ba ll M ult i- G o a l.


Pet R o.

22-29 4

Wo o d cu t & Co._ _


9004 R ed esign .




C A D & LP / LT D evelo p m e nt.

48-51 5

Chill Media Innovations Chill media combines conventional refrigeration with a high definition display to enhance the standard fridge appliance. Founded in 2012 to innovate in the home, the combination of chillers and media messages is one we’ve worked hard to bring to fruition with applications both domestically and commercially. The simplicity of our media fridges make them the goto solution for getting your message across to your audience.


CM1 Smart Fridge Everyone’s kitchens can be busy places and we like to leave notes for people, to have a calendar shared with others, to show photo’s, postcards, drawings and memories made together. We like to check news and weather on the way out in the mornings and use the internet for recipes, videos and just entertainment in the evenings. This fridge offers a new way to do all of these by taking a device we’ve all got already plugged in 24-7 and opened 15-20 times a day to bring all these features to your kitchen.


Home Screen

Notes 7

CM Commercial Products CM Commercial products allow for consistent or varied messaging across multiple venues to suit any environment.

Revenue Generation

Easy Setup

Multi Screen Synchronisation

High Definition Display

Simple Installation

Software Development Software design of CM Commercial Products using Python to develop multi screen synchronisation, scheduled content updates & more..

Scheduled Content Updates Simple to install and remote content management services available.

Multi Screen Synchronisation Automatically synchronises across multiple units for an eye-catching display.


Single Sync

Landscape Sync

We b D e s i g n HTML | CSS | JavaScript


Hunting | Observation | Security | Search & Rescue


Nitesite & Nocturna Ltd Nitesite and Nocturna Ltd are part of the Queen’s Award for Enterprise: International Award Winner 2016, IRNV Group based in York. UK. We specialise in innovative and cutting edge infrared night vision equipment. Our team invents, designs, develops, manufactures and delivers to the world marketplace from our UK base through an established global distribution network. Utilising ground breaking IR technology, we offer the most comprehensive, affordable night vision solutions on the market today.

- Drafting product assembly explosions for production SOP’s, and technical drawings for tool makers

A three part button to convert rotary motion to linear motion

Mechanical System Development Development of mechanical systems through sketching, TurboCAD and 3D prototyping. While considering DFM and DFA methods to reduce costs and assembly times.


Shenzhen, Guangdong, China

I n t e r n a t i o n a l Tr a v e l International travel to Asia, to locations such as Hong Kong and Mainland China to source components and speak with existing suppliers through factory visits. Also contacting suppliers to source new components, and look towards reducing costs of existing components.

Electronics Designing TTL communication between microcontrollers through the use of flowcharts, state table logic & basic schematic diagrams.


3 0


4 0

1 Bit


2 Bit

3 Bit

4 Bit

5 Bit

6 Bit

7 Bit

8 Bit

9 Bit

10 Bit

PCB Design 3V & 9 V I R L E D P C B

P C B B o a rd

G e r be r L aye rs

S che m at i c D i a gra m

PCB design using Eagle CAD to be used in both prototypes and manufactured products. 13

Foot b a l l M u l t i - Go a l Sma l l Si ded Fo o t b a l l - J u n i or - Mi n i S oc cer

A telescopic goal designed for a wide range of small-sided, junior and mini football games, that can be used both indoor and out, easily adjustable with fast and simple assemblage.


1st Place Winner Sapa 2017 Design Competition

Leisure & Park Cuts


UK Football Pitches

51,165 Sports Participation of Adults Aged 16+ (Mintel, 2016)

Football - 4th Biggest Sport Played 15

Concepts & Development Prevent twist by creating grooved shape in the extrusions and countersinking fixing methods to eliminate pontential harm to user

Deciding on fixings A clevis pin & r clip fixing method was chosen, as it removes the need for the fixing method to be maintained since it does not gradually wear like a nut & bolt. 16

Calculated lengths of extrusions needed in telescopic joints to create goal sizes required and ensured it complies with all relevant British Standards. BS 8462:2005 & BS EN 748:2013


*ANSYS Simulation* British Standards states that a crossbar should not deform more than 10mm when tested under 1800N. By including a factor of safety of 2, max deformation was 5mm. Ansys (FEA) was used to calculate and find the ideal crossbar structure. It was found that having corners of the crossbar intruding into the centre crossbar by 1590mm, resulted in a max deformation of 4.8mm, which met the specification. 17



Clevis Pin M8 x 70mm

Front Goal Sizes

4.88m x 1.8m


R Clip

3.66m x 1.8m

Unit Costs:

100,000 Units: £227.94 10,000 Units: £228.66 1,000 Units: £235.86 Ca - Support Beam Assembly B1a - Corner Assembly




B2a - Corner Assembly x2

B3a - Corner Assembly x2

Clevis Pin M8 x 70mm

Net Clip x30 R Clip



4.88m x 1.2m

3.66m x 1.2m

Underside Goal Sizes

Aluminium 6060 T6 Cross-Sectional Views (mm)

Net Clip

A B2a

White Powder-coated

C1 C2

B Ca

C1 Net

76 Dry Film Lubrication


20 x 30

White Powder-coated



White Powder-coated

B1a B3a




£1,499.99 A1 - Crossbar


A2 - 1.8m Uprights A3 - 1.2m Uprights


x2 x2






2 Slide connecting A and B parts together


Fix together with Clevis Pin and R Clip

4 Slide Support Beams into A2 and A3 parts

Twist net clips into position and attach net

Pull uprights apart

3.66m x 1.2m 20

3.66m x 1.8m


Photo for illustration purpose only



Push uprights together

4.88m x 1.8m

3.66m x 1.8m Tip goals into new position


Remove and reattach clips and pins when changing goal sizes 21

Newcastle, UK 22

Dr Ben Salem Jonathon Stelling Eliot Quinn Tarik Safir Kit McBride


The earliest version of the PetRo concept was in 2000, a caltrop shaped omnidirectional modular robot. The (long-term) aim of PetRo was to reach a throwable and self-assembling design, which could be used for a wide range of applications such as search & rescue and inspection & surveying. The initial ideas and developments were conducted in 2000-2001, since then prototypes I, 2 and 3 have been developed. We are currently developing the concept into a series of demonstration prototypes. The main motivation behind the project was the need to deliver a robotic platform that allows for field applications away from controlled environments, requiring both reconfigurability and high-mobility. We also wanted to minimise the handling and care required by the robot, with the long-term aim of a throwable robot.


3D printing and testing parts allowed us to improve their overall strength and the types of fits they had with other components, subsequently allowing the testing of selected stepper motors and drivers. Other things we began to test were the end plate communication, specifically how each module will communicate with each other. We decided to use asynchronous communication to send data between the two modules since they will not be on the same local clock, so this method will help to synchronise the start and end of each byte sent.

I have been working on the ‘Petro 3’ modular robot prototype, helping to lead a design team focusing primarily on the mechanical and control systems of the robot. To create the prototype, we used a variety of CAD software. The project enhanced my skills in technical writing of documents, using 3D CAD models and creating complex animations and renders. We’ve presented the prototype robot at the ‘RO-MAN’ conference in Edinburgh, U.K. 24

- Cur rent ver sion Pet R o 3 .1 3 25



A modular approach offers many benefits. The availability of redundancies allows damaged modules to be discarded, thus improving reliability. This redundancy is also a contributor to addressing a potentially limiting power supply, by allowing the re-distribution of power amongst modules. Another benefit is the adaptability of the robot, which goes as far as reconfigurability in terms of overall architecture and thereafter offer variability in gaits and motions available. 26

D et ail A Cross-S ec t ional View

Omni Wheel LED Metal Plate Contacts Push Pins Phototransistor

Power to Release Magnets

End Plate 27

A screenshot of the movie of Rubin, a 9 years old male Border Terrier, expressing fear.

A third benefit, specific to pet application, is the metaphoric growth potential the robot possesses, achieved by adding modules to the assembly - an interesting fact from a commercial perspective. The bi-modular configuration yields a dog-like appearance, inspired by the body language and expressions from dogs’ body movements. We see this language as a means to provide feedback that is intuitive, natural and can potentially reinforce an empathic connection between user and robot in an analogous pet-owner relationship.

A screenshot of the animation of PetRo expressing fear (Shoulder in green, Hips in red).

We focus on the following emotions: anger, curiosity, disgust, fear, happiness, and sadness. All, but one (curiosity) are basic emotions, evidenced by the functional neuroanatomy of the brain. Contrary to what has been said in literature, we do not consider surprise as a basic emotion. Furthermore, while curiosity is not a basic emotion, we have added it due to its highly relevant proposed functions of the robot. We also include the following artificial moods: ready and low--power. 28

PetRo has multiple applications including companion pet, search and rescue, and in general applications where it is difficult to predict the theatre of operation in which the robot will be used.

PetRo’s Multimodal Emotional Language was presented at IEEE RO-MAN 2016, The 25th IEEE International Symposium on Robot and Human Interactive Communication.

Columbia University, New York City, US


Intu Metrocentre, Newcastle, UK 30

Jonathon Stelling Ghitya Amrita Joseph Norton Ravensca Rintiarna Gessayu Setiawan Alex Vescio @woodcutandco Woodcut & Co 31

Classic Collection o Earphone Holders o Keyrings o Coasters Seasonal Collection o Christmas Decorations o Valentine’s Day Accessories

- Elephant Keyring, Classic Collection

Six Northumbria University students, including myself, created Woodcut and Co, a start-up wooden gifts manufacturer and retailer located in Newcastle-upon-Tyne. With an initial cash injection of ÂŁ200, we were able to fund our business start-up without any external investment, making this business idea viable whilst still attending university. By using a laser cutting machine and locally sourced wood, we created our product range. As well as our leading classic and seasonal product collections, we also aimed to offer a unique, personalised product service to customers, exploiting a niche in the market compared to other sellers. 32

“Our mission is to provide customers with high q u a l i t y, a f f o r d a b l e , w o o d e n g i f t s �

As well as creating new and exciting design ideas for products and amongst other things, my main role in the business was web design, creating marketing content, dealing with customer queries and managing social media accounts like: o LinkedIn o Facebook o Instagram o Twitter


90 0 4 Redesig n

The 9004 Britax Rear Combination Lamp has been a widely sold rear light all over the world for the last 20 years, catering to commercial vehicles as their go to aftermarket lamp. As the years have passed, technology has changed and so has the company that owns the 9004, creating a need to redesign the product. The new design incorporates the latest in lighting safety and technology, addressing issues such as suitability and technology trade-offs, reduced product depth and has helped to secure a promising future for not only the product, but for the company as well.

Northumbria University, Newcastle, UK 34


Background Britax was created in 1939 by Philip Metcalfe Godfrey Thorpe back when it was first called PMG Thorpe, where they produced electrical equipment for the automotive industry after the war. In the mid 1970’s, the car safety equipment manufacturer Britax took over.

Current Product & Its Limitations

Old Technology|Halogen Bulbs Inefficient & Require Maintanence


Large Depth

Increased chances of product damage 36

Company Background & Takeover Britax, a car safety equipment company, which has been in business since 1939, was officially taken over by ESG in April 2017. ESG is the world’s largest manufacturer of commercial and emergency vehicle warning and safety products. Their aim since taking over Britax is to rebrand all of their products to their main commercial brand, ECCO, and redesign products to better meet the their brand and values, such as product quality, design and innovation.

Research & Consulting Experts Initial research and consulting experts from CS Auto Electrical Parts UK helped to find out users key needs & wants from the 9004.

Users Key Needs:

Minimal Safety

Uses the very basic safety requirements for road use

Poor Sustainability

Affordable Meet Standards & Regulations Long Lasting -

Users Key Wants: Features new technology Current Waterproof Thin Bright & safe


Poor use of fixing methods & materials 37

C o nc e pts & D eve lop m e nt Before major factors like cost and viability were introduced, a concept classification tree and mind mapping were used to introduce every possible idea and new technology that could be applied to the 9004. A morphological chart followed, creating individual concepts from these ideas.

LED Technology was chosen to be taken forward after all factors were considered. OLED Technology will be considered in the future when it becomes more viable.

Side & Rear Indication OLED

Wireless Charging

Warning Messages

Sweeping indication was taken forward due to its increased road safety and market trend


Sweeping Indication

Casing Development Case fixings for the base and lens were then developed, identifying that no maintenance was required for the new technology. Sustainability and end of life considerations were used to help to also choose a fixing. After testing and more research, the most effective snap joint was used in the lens and used the base as a lip for the snap feature.

The selected snap joint can still be molded using just a two part mould and doesn’t require any extra moulding actions Sweeping indication fully activates 90ms before a standard halogen bulb


Sweeping Indication

Time 39

Final D e s i g n

Standards & Regulations Marking

Company Logo Marking


Top View

65mm 10mm 15mm 28mm

Side View

Front View

Steady candela level 80°¹ from reference angle

67mm Bottom View Helps end of life process & fitters -

Tec hnica l I nfo r m at i on 40



Reflex Reflectors



Snap Joint

Reflector O-ring


PCB Rubber Grommet

Vent Washer Nut Cabling



Allows for the passage of air into the assembly, reducing pressure and moisture build-up, ensuring long LED life (IP67)

E x pl oded View 41

- *Visual Render w it h S uperimposed P ho to of Work ing Protot y pe*


Depth reduced by

66% 91%

Energy efficiency increased by

B r a ke L a m p

Position Lamp

Increased Safety


Pro tot y pi ng

L ED ’s & c irc u it prototpyi ng , co ntro ll ed by A rdui no mi c ro co nt ro l l er

L e ns pro to ty pe d by c re ati ng a 3D pri nt using clear resin, t he n sa nde d, po l i she d a nd sprayed w it h t ransparent s pray pa i nt

The addition of sweeping indication helps to provide better visibility for road users and pedestrians. Swe eping Indicat ion

H o ri zo ntal M o unti ng

*Photos taken of protot y pe*

Vert ical Mount in g 43



A global game of tag that can be played wherever, whenever Tag, also called touch or tig, is a children’s game in which the player who is “it” chases the other players, trying to touch one of them, thereby making that person “it.” I knew that I wanted to take my interests further into wearable tech, so I decided to create a game of tag on a much larger scale. The idea was that the game would be played throughout your everyday life, so whether you were at work, or at college, you would still be playing and could be tagged at anytime.

New Jersey, US 45

P roto ty p in g & Test i ng The idea for my first prototype was to use a micro-controller to record the data from each player. Capacitive touch sensors would be placed in the shoulders of each player, and would be used to detect users touching one another, sending that data to the cloud. The game dashboard would then ask the cloud for data, with the data received back being sorted and displayed on the page to the user. Capacitive Touch Diagram Waiting for player number... Status: Offline Waiting for tag data... IP Address:

Player 1 Status: Online Times tagged: 0 IP Address:

Asking for data

Conductive fabric in shoulders

Receiving data

Particle Photon microcontroller used to prototype

Player 1

Player 2

Testing environment 46



Responsive images to change in response to data pulled by Javascript



if (json.connected==true){ status1=”Online”; document.getElementById(“status1s”).className = “opacity100”; } else{ status1=”Offline”; document.getElementById(“status1s”).className = “opacity50”; }


The Cloud Receiving JSON data

Requesting JSON data


Lens Modelling Recreating early 1990’s light lenses from complex 2D drawings into 3D CAD files for FEA analysis and retooling, to improve and correct the injection moulding manufacturing process.



L P/ LT D e v e l o p m e n t LT B eaco n L E D

Designing and developing products such as the LP/LT LED Vehicle Beacon range. LP/LT LED Beacon range: Screw thread, o-ring & screw lock fastening mechanism Polycarbonate lens and ABS base Improved fresnel feature

L P B e aco n L E D


LP/LT Beacon 5W xenon

Locking Mecha ni sm

C ro ss- Se c ti ona l V i ew


PCB O-ring

Screw & o-ring Fixing bolts Base


Jonathon Stelling +447527351353

Jonathon Stelling - 2018 Product Design Engineering Portfolio  
Jonathon Stelling - 2018 Product Design Engineering Portfolio