portfolio Khush Kapadia M.S. Design Science, University of Michigan khushk@umich.edu
Accessories and trinkets The X-Brace Case A press-fit case for the iPhone, with a flip-out stand was designed to be 3D-printed. The flip-out stand has the ability to rotate 90°, giving the user the ability to stand the phone either vertically, or horizontally. The design cycle of this product included verifying the dimensions of an iPhone model with the real deal, followed by iterations of the snap fit design for the stand.
A PCB Soldering Vice This vice is designed to be low profile with its folding arms. On of the arms is fixed at one end, and the other has the ability to ratchet back and forth to create a precise fit for a PCB ranging in width from 1.5-2.5 inches. The groves in each arm hold the board in place.This model is also scale-able on the print bed to accommodate for a larger PCB.
Laptop Stand A quick search for laptop stands revealed products that either increased the height, or were too bulky. This stand solves the issue by creating a sleek sheet metal stand that can be dye cut and formed into the profile.
Don’t get too warm A wall mounted fan unit that offers all the features a tower fan does, without taking up the room on the floor, and providing more coverage.
Inspira�on The buttons are designed to successfully communicate the functions without descriptions.
The inspiration for this design came from a personal invocation for a wall mounted version of a tower fan I was browsing to buy. The options available didn’t fit the This design takes influence from the internal components of a floor-standing tower fans, and marries them with the casing of a wall mounted AC Unit. The final product comes out to be a sleek unit that can be controlled via the remote with 7 speed settings. The oscillating function allows the air to be distributed evenly through the space.
A high durability motor is to be utilized to ensure operation for long hours without overheating.
Product Modeling and Realiza�on The air intake was moved to the front of the unit to allow for mounting at the corner of a wall and ceiling.
The oscillating function is made possible by curved blades that direct the air flow as desired
The Whispr Singing Mask For any singer who wants a comfortable and private prac�ce experience, Sing your heart out — wherever, whenever! Conducting market research that included amateur singers and vocal majors, it was found that singing in a shared space induced anxiety in the individual and hindered successful singing practice. This product aims to provide a private singing practice experience by reducing the sound from the singer while providing them with functionality to monitor their singing and recording it for review.
From market research, it was found that the functionalities offered by Whispr were found in products such as the Belt Box and HushMe. However, neither of the products performed to the desired level of the Whispr Mask, so it justifies the product to fill the market gap. The gap would be filled by a high sound attenuating product that has a high comfort index that can allow for longer practice sessions.
Conceptualiza�on In conceptualizing this solution, the first few iterations varied in shape, form, and execution of functions. Ranging from ellipsoid booths using geometry to attenuate sound, all the way to solid masks with integrated headphones.
Using weighted selection processes with customer requirements, the design was materialized as a two-part solution with a shell that housed the electronics and an internal dampening unit.
Detailed Product Development
Development Parameters
Using Anthropometric Parameters To size the mask fitting a user’s face, the contact areas were sized according to parameters determined through a national study from the Computers and Industrial Engineering Journal. Specifically, measurements used were number 1, 2, 6, 10, 22, and 27 as shown.
Material Testing for Sound Three available materials were tested against each other to select the maximum sound reduction in a testing rig . Recycled Polyester Fabric board came out on top.
Prototyping and Tes�ng The prototyping efforts for this product began with an alpha prototype that communicated the form and fit of the product on the user’s face and its construction. Once the general shape and dimensions were established, the 3D model was developed and iterated with the help of rapid prototyping to finally create the fully functioning proof of concept that attenuated the sound by 17dB while demonstrating the live audio monitoring, recording, and playback functionality,
Sound Absorbing Lining
Flexible contact material
Alpha Prototype
Fully Functioning Proof of Concept Connector pegs
Product Descrip�on Microphone Hole
Nose Rest Breathability Holes
Strap Holes
Breathability Vents Buckle
Po we Buttons placed withr
ease of access, and uniquely textured for use without visibility.
Power Record Playback Audio Monitoring Headphone Jack
The ADA Fin Project Problem Posed The adaptive diving association uses the fins that attach to the arm to give paraplegic people an alternative tool to maneuver as they dive. Original Fin in Use
The ADA did not have the ability to reproduce the same for their increasing members. Our team was posed with a request for a new design and development process to create these fins that are easily reproducible, and have the ability to be made custom to each diver’s grip. The Pins and Holes come together to form a snap fit, attaching the 3 parts together.
The Fin was designed in parts to allow for printing on medium sized commercial FDM printers, Like a Prusa 3D Printer.
The slots fit straps that wrap around the arm to create a snug fit during swimming
A revamp of an exis�ng diving fin that is worn by paraplegic divers. The redesign takes into account both the advantages and limita�ons of FDM Addi�ve Manufacturing
Advantages of Addi�ve Manufacturing One large advantage of AM is Free Complexity. This means that there can be added complexity and personalizing capability without a large impact to manufacturing costs. This revamp takes advantage of this free complexity by creating personalized grips to the fins. There would not be a large impact to the manufacturing costs if we chose to create the custom grips to a generic grip. Modeling clay pressed to capture the natural contours of the hand
A 3D printed model of the grip that demonstrates the custom fit.
Pressed Clay set up for 3D scan
Crea�ng the Custom Grip
The scanner creates a 3D model of the grip via a combination of lasers and cameras The 3D scan of the mold is now brought into the model, scaled, and placed onto the handle as measured from the mold.
Collaboration in Extended Reality
Collabora�on tools reimagined in an extended reality space to facilitate social interac�ons and expand the horizons for conceptualiza�on tools and methods.
A chat function that can attach files, images, and links to items in the folder structure. Users are grouped by teams on projects.
Holocall, where users can come together in a three dimensional space. The home screen has all the meetings displayed, with an option to schedule a new meeting and also start an instant call. When in the call, the users are able to add other teammates, open a Jam board, take down meeting minutes and add tasks, which are stored on the filing system and are shareable across the platform. The Jam board creates a new space where the collaborators can create sketches, diagrams, and share ideas in a 3D space with their avatars shown. The interaction in this format can foster improved communication.
The task tracking function allows the user to create tasks where one can assign due dates, people responsible, add a description, and relevant files. These tasks can then be classified per project and their status, editable per user as the project progress.
In the past years I have had the opportunity to bid on, design, and manage HVAC projects for office buildings.
H V A C Design
This process includes designing systems from the ground up–based on the heating, cooling, and ventilation requirements of the buildings as dictated by code and bestpractice methodologies, leaving room for innovation and valueengineering.
Systems design Throughout my role as a project engineer, I have had the opportunity to design, calculate, lay out, and help manage the construction of HVAC system for commercial and office spaces. These projects have given me the opportunity to understand the life cycle of a design, from ideation to completion. Along with practical experience, the theoretical training I received taught me about systems that included central utility plants, and understanding the living-breathing nature of any system that is created to serve people. Any system or a product that is created must take into consideration the nature of human interaction with it and mold its design for seamless interactions.