TOASTER REDESIGN - MATTHEW HORNSBY

TOASTER PORTFOLIO MATTHEW HORNSBY 07855775651 M.E.HORNSBY02@GMAIL.COM

HI.

I’M MATTHEW

I am a Product Design student currently 2 years into my degree at Aston University.

This is a short portfolio showcasing my end of year 2 project.

Thank you for taking time to look through my work if you would like to get in contact with me please find my contact details on the cover.

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OBJECTIVE The intention of the project is to research and evaluate existing toasters and redesign a new product improving user interaction. This was achieved by analysing the current interaction between the user and the product, understanding the design for manufacture and the engineering principles behind its function. The re-imagined toaster must be designed to last 25 years to improve sustainability.

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IDEATION

As part of the research and ideation phase I disassembled an existing toaster to understand the engineering principles behind the function of the toaster.

I also used this toaster for several weeks taking notes and observations to create a task analysis. This allowed me to analyse the user interaction with the toaster and identify improvements to consider when redesigning the toaster.

Taking inspiration from classic cars and modern robotic structures allowed me to create these interesting forms, some of my initial form sketches are shown on the right.

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FINA

AL DESIGN

MIURA

The Miura toaster brings quality and sustainability together to provide a quality toasting experience. With a guaranteed warranty of 25 years the Miura toaster is aimed at protecting the future of our planet and improving the toasting experience compared to current toasters available.

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1.

Plug toaster into mains power supply and power toaster on by tapping the centre of the dial.

3.

Once the bread is loaded in the toaster, set the time you want to toast your bread for using the dial. This changes the max capacity in the capacitor therefore how long till the circuit will be cut off.

4.

Using the tab on the front of the grill, pull the grill out to place bread onto the grill. This feature allows the user to easily place the bread onto the grill. This design also accommodates for other food such as baguettes or toasties.

2.

Select which mode is desired, there is a selection of modes available including defrost, reheat and baguettes.

To change mode pull the dial out one ‘click’ and then turn to cycle modes.

Mode icons will appear on the digital screen.

5.

Once the timer runs out the circuit will cut off dropping the grill, fold down the front of the front cover to let the toast slide onto the plate. If you want to stop toaster before the timer runs out pull the dial out another ‘click’ to cut the circuit.

COOLING FANS The fans draws the hot air away from the dial where the user will interact with the product. A vent is placed above these fans in the outer casing for the hot air to flow out.

MATERIAL: Casing PP / Blades MANUFACTURE: Injection Moulded / Steel COLOUR: Black / N/A FINISH: Matte / Brushed

INTERNAL COMPONENT CONTAINER This part contains all the electrical components including the motor and electromagnet. The container stops these parts from moving around inside the toaster and prevents them from getting too hot.

MATERIAL: PP MANUFACTURE: Injection Moulding COLOUR: Black FINISH: Matte

INTERIOR CASING FIXINGS The interior casing allows the components to be fixed to the outer casing. The casing fixing screws into the base of the outer casing and into the component shells.

MATERIAL: PP MANUFACTURE: Injection Moulding COLOUR: Black FINISH: Matte

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INTERNALS

HEATING COMPARTMENT The heating compartment contains and reflects the heat to protect internal components, stopping the outer casing from getting hot and also to improve the cooking intensity.

MATERIAL: Stainless Steel Sheets MANUFACTURE: Water Jet Cutting FINISH: Fine Brushed FILAMENT FIXING AND PCB COMPARTMENT This casing holds the filament and fixes it to the back of the outer casing. It also holds the PCB boards for the dial screen.

MATERIAL: PP MANUFACTURE: Injection Moulding COLOUR: Black INTERNAL DIAL COMPONENTS FINISH: Matte The internal dial components is made up from several parts to complete the functions of the dial.

MATERIAL: Stainless Steel / Iron MANUFACTURE: Die cutting FINISH: Fine brush HEATING FILAMENTS The heating filaments toast the bread, an electric current flows through the filament releasing infrared radiation.

GRILL HANDLE The grill handle allows the user to lift and remove grill without touching the grill.

MATERIAL: PP MANUFACTURE: Injection Moulded COLOUR: Black or Cream FINISH: Glossy

INTERNALS - EXPLODED

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PRODUCT - EXPLODED

DESIGN FOR MANUFACTURE

Die casting is used to create the internal shell, this will allow the desired curved shape to be obtained by using a mould tool. Die casting will allow high rates of production with little machining required. Die casting will provide a part that is durable with a feel and appearance of quality.

The heating chamber parts are made from stainless steel sheets, these parts will be cut by water jet cutting, then treated and bent to create the part needed.

This allows for the heating chamber to be made and assembled without any adhesives, and is hold together with fold able tabs.

This allows these parts to be easily recycled and re-cut to be used as different products or melted down.

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Injection moulded parts have bossess and ribs to reduce surface sinking and to add stability to the product. A draft of 1 degree is also needed on each surface to allow the mould tool to be released from the injection moulded part. As these parts will not be visible from the outside of the toaster the injection point and pin marks don’t need to be hidden.

Using injection moulding allows for flexibility in the shape and form of the part produced. It also allows for the part to be recycled and remelted down if damaged.

The Miara toaster will be able to meet the 25 year warranty with a focus on sustainability. To be able to meet the 25 year warranty I focused on the reasons why current toasters do not have a product life as long as this. The biggest issue is that they stop working or the quality of the product declines over years until the toast produced isn’t satisfactory. Replacing toasters this often has a negative impact on the environment,reducing the amount of toasters thrown away would save materials, reduce manufacturing CO2 emissions and transport emissions. Therefore I focused on this issue when I started to work on a solution.

The idea that I have gone for is to make it accessible and easy for the consumer to be able to repair or replace the internal components of the toaster. This means that any issues with the operation or quality of the toaster function can be easily fixed instead of throwing away the whole toaster with some useful components and materials. Another benefit of this design is it makes it easier to salvage and recover parts from the toaster so even if it was to be thrown away components and materials can be easily extracted and separated to be properly recycled and reused. The left cover easily comes off exposing all the internal electrical components, the design of the fittings of the internal casings allows the user to easily remove the components without the need of removing screws or damaging any parts. This helps to ensure the toasters components are damaged and stay in a safe condition to be reused again.

MATERIALS RELEVANT PROPERTIES • High heat resistance • High chemical resistance • Low weight • High surface strength • High electrical resistance

I chose to use aluminium as the inner shell of the toaster, due to the high curvature shape the material must be highly capable of being shaped and bent. Aluminium also has a low density and ductility.

Aluminium s highly reflective surface finish also ensures to limit any heat loss by reflecting any escaping infrared rays.

RELEVANT PROPERTIES • Low coefficient of Thermal Expansion • Increased aesthetic • Good heat insulator • Limited shattered pieces

Due to the materials high corrosive resistance it will be able to last the lifetime of the product and be recycled at the end of the products life.

I chose PP-30GF due to its high electrical and heat resistance. As the these parts will be in close proximity to the heating compartment.

All the parts made from PP will also be injection moulded therefore I had to pick a thermoplastic that can be used for injection moulding effectively in manufacturing.

Polypropylene is also readily available and fairly inexpensive.

To meet the requirements of the 25 year warranty this material will be durable and last the life time of the product. It will also e bale to be recycled and reused at the end of the products life.

RELEVANT PROPERTIES • Malleability - highly capable of being shaped and bent • Thermal expansion coefficient of 23.3 • Corrosive resistant • Low density • High ductility

I chose to use stainless steel for the internal heating chamber as its non corrosive meaning cleaning products can be use don it, its also easy to clean therefore making it easy for the user to clean any crumbs or food residue after using the toaster.

Stainless steel remains strong at very high temperatures. Its reflective finish ensures there will be limited heat loss ass all the infrared rays at internally reflected back onto the bread.

Its durable and will last the life time of the product of 25 years, it can also be recycled at the end of the products life.

I chose to use heat strengthened frosted glass because it has a good heat insulation to reduce any heat loss from the toaster. It has a low coefficient of thermal expansion, this is important as the glass is going to be close to the heating filaments therefore if the glass expands too much it may shatter or distort parts of the toaster.

As this piece will be moving on a hinge I took the shattering pattern into consideration in-case this piece is accidentally dropped or smashed. Due to the heat treatment the shatter pattern is limited pieces this is safer for the user and easier to contain.

RELEVANT PROPERTIES • Non-corrosive • Easy to clean • Recyclable • Strength at extreme temperatures • Reflective

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CONCLUSION Designed to be easily de-constructed and repairable without training, improves product life time improves safety and sustainability reducing material waste and manufacturing.

Improved user interaction, enclosed shape reduces heat loss compared to current toasters decreasing the cooking time and increasing efficiency.

New dial design allows for ease and tailored use of toaster.

Re-moveable grill and front cover allows for easier cleaning of toaster improving ease of maintenance increasing hygiene and product life.

Designed for high efficiency manufacturing, use of die casting and injection moulding for efficient mass manufacture.