2021 Product and 3D Design Portfolio Max Hearnden

Welcome I’m Max, an interdisciplinary Product Designer and Graduate from Loughborough University Design School.

This portfolio contains projects that best represent my skills and aspirations as a designer, please enjoy.

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Education

Employment

Loughborough University Product Design Technology BSc 2014 - 2019

Front of House Staff Digme Fitness,

Grade: 2:1

3D Concept DesignerESP Fitness

Modules: Design Practice, Computer aided Ergonomics, Design Communication, Design Research, Design Contexts, Computing for Designers, Design and Manufacturing Technologies, User Experience Design, Further Mechanics for Design, Electronics, Programming and Interfacing for Design and Prototyping for Design.

Bar Staff Marston's PLC,

May 2017 Jun 2018

Sept 2015 Jan 2016

Event Staff 81 Events, Henley-on-Thames,

Summer - 2017,18,19

Software Skills Shiplake College 2009 – 2014

Sept 2019 Mar 2020

CONTACT

A Level & GCSE

Volunteering LSRC Committee Media Secretary and Vice President 2015 - 2019 Leicester Rowing Club Women’s Coach 2018 - 2019

+44 (0)7827525313 maxhearnden@gmail.com

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Final Year Design Project

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IoT Design Project

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Design for Manufacture

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Gym Design and Fitness Equipment

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Interior Design Renders

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Aim: To grow and improve the sport of Rowing Brief: Design an accessible and fully automated race timing system for domestic races in the UK Main Hurdles: Cost of implementing technology and Teaching myself Python

_Supported by

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REGATTA LINE TECHNOLOGIES

_Automatic Race timing system for Rowing and other Water Sports

The Problem Timing and the production of results is the longest standing issue facing amateur racing in the UK. It discourages spectators from attending events and causes race times to be unreliable .

The Regatta Line camera system works “Hey, I’m by providing all competitors with a unique Jason” QR code to be read by computer vision software run through a high-speed camera at either the start or finishing line.

Currently Races are timed using stopwatches and recorded on paper before being manually added to a spreadsheet to calculate results This is time consuming & inaccurate.

The Solution QR Codes • Cheap to produce • Read at a distance of 20m • Water and damage resistant • Race number can be added • Technology already exists • Can store 4296 characters • Potential for development ‘Implementing an efficient and accurate timing system is one of the longest standing problems in our sport’ - Ben Townsend - Events Chairman for Wallingford Regatta and Head Races

96% ‘Top teams in the UK conduct their own timing at races as times can be ± 5 sec over long distances and can take upwards of 2 hours to produce’

Research:

of UK races are held on small Rivers and Canals

Interviews, Shadowing and netography were used to analyse the main issues and pain points facing the sport. User insights and other data were evaluated to help generate multiple product concepts that were then put against the Product Design Specification in a concept selection matrix. Due to the relatively small Rowing market it was later decided to design the system to incorporate other watersports as well.

Ideation/ Concept Generation

_3 different concept directions to solve the problem of race timing

Prototyping and Testing Electronic Prototype -

QR Code on craft

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Range: 1.82m

Administrative App

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Live video Stream =

5+6

7 1. 10,400mAh 5V, 1A Battery 2. Raspberry Pi 3B+ 3.

7 inch Touch screen display for Raspberry Pi 4.

3V Pietzo Buzzer 5+6.

Wireless mouse and Keyboard 7. 8MP Pi Camera 3 module 8. 3V Cooling fan positioned over heat sinks. 9. 15cm Lightweight mini tripod

Accurate timing

Ergonomic prototype was used to test: • Handle Orientation • Size and weight parameters • Chord extension length • Button placement The model consisted of 11 individual parts and was made using a friction fitted FDM printed PLA sub-structure. An internal weight was added to simulate the centre of gravity and mass.

Used to show the feasibility of the technology and provide a platform to scale up hardware for development

Ergonomic Prototype

Aesthetic Direction

Why it is needed: Amateur sports quickly fall behind the technological advancements of professional sport.

Current trends show the inclusion of technology in sport have increased the number of viewers and fairness of the competition. (e.g. VAR, Hawkeye, DRS)

General Setup 1

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As a minimum, one camera must be used for finish detection but multiple cameras can be used for split timing and one for the start line.

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Cameras connect via Bluetooth / WiFi to bespoke operating system run on network connected tablets and feed to mobile App.

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Digital Finish line setup creates detection zone for craft as they make their way up to the Start line.

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QR code detection and Live video at the Finish projects number and crew to live results App.

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If racing is close a photo finish can be toggled and times taken from that.

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Design for Manufacturing & Assembly

Market

300 Rowing and 200+ Sailing regattas held annually in the UK. Private Schools, Universities, business clubs and well funded boat clubs organise races running year-round. Potential users range from 18 to 80 years of age and can use a simple tablet based App interface.

Costing

Using Herbert Rondeau’s 1-3-9 rule for cost estimation in design a production cost of £1750 per unit minus development costs.

Clubs would expect to pay upwards of £180 for the implementation of the technology depending on the level of supervision needed. After development and reliability testing production rates are as follows:

Manufacturing Proposal

Low volume batch production is necessary using an in-house Selective Laser Sintering machine. Industry standard fixtures and fittings will be used with PCB mounted bosses included in a soft mould tool or adhered to the 3D printed Nylon casing.

During the development of the final design a Prototyping CAD model was used to iterate minor changes before a Commercial assembly was created. Care was taken to minimise changes in wall thickness to allow for injection moulding if necessary and a reduction in volume for SLS 3D printing costs.

Second stage of project design

Features

• WiFi and Bluetooth connectivity to avoid dropouts and increase range.

• IP connectivity and UDP transport for low latency connectivity between cameras.

• Spectator App for watching the live video feed at each camera position and live timing of an event.

• Universal mounting points on camera handle for attaching different camera rigs and DIY operations.

• IP64 rated casing and fittings.

Hardware

• Sufficient internal power reserve.

• Large external anodised heat sink.

• Solid State internals.

• Outsourced Industry standard high fps camera.

• Durable momentary switch and slide switch on controller connected with Spiral Wrap Wire.

Timing

• Video timing backup.

• Accurate to within 0.01 seconds.

• First amateur photo finishing system.

• Haptic feedback to avoid misfiring on the App. • Multiple marshals can provide progressive split timing if necessary.

Aesthetic Model

Head of The River Race (Largest Participation Rowing event in the UK)

We keep looking out for a system that will capture times and crew identities automatically, but we have not yet found another system that will handle hundreds of possibly overlapping entries competing over a wide stretch of water. GPS we do not find to be accurate enough and the devices are expensive. Video is still unable to digitalise boat numbers and associate them with time.

But we are open to suggestions!

T R A C ONE WEARABLE TECHNOLOGY

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INDIVIDUAL DESIGN PRACTICE Divided

TRAC is my contribution to the internet of things.

It replaces the need for multiple wearable devices to gather data on an athlete’s performance.

Main features include:

Sharp

Accurate Heart rate, GPS, accelerometer, magnetometer compass and WiFi connectivity.

Interchangeable strong Medical grade adhesive tabs (1 week).

Geometric Faceted

Understanding the form is a very important part of a design direction. Translating certain aspects of design creates a design language with which a brand can be established.

Incorporating split lines and interaction points into the form was a key part TRAC’s design.

Ergonomic shape and position prevents catching and allows ease of application.

Induction charging.

One button press and hold interface.

Compression moulded soft silicone rubber body.

TRAC

The Initial problem that I chose to address in the Sport Wearable market was the fact that every product uses a strap and this clutters the user and restricts their movement whether it be on their wrist, chest or ankle.

The second problem with dedicated sports tracking systems is the fact that a vest/ harness must be worn in addition to hold the devices. This can negatively effect the performance of athletes by increasing their core body temperature and further restrict movement.

TRAC is the combination of GPS and Heart-rate monitoring in the most effective small ‘attachable’ The device is positioned under the pectoral muscle or below the sports bra line to give the most accurate heart-rate reading.

The soft Silicone rubber body allows for the device to flex and mould itself the body of the wearer. The silhouette of the design resembles the Apex, Left and Right Ventricles of the Heart.

_Appearance Model, ProLab + HIPS

GPS systems are used in a multitude of sports and allow for extremely accurate player tracking. With data from the device it is possible to generate heat maps, player exertion ratings and instantaneous power output with up to 25 points per second data output.

TRAC is large enough to use an ECG system identical to most chest straps and heart rate monitors. This isn’t the most accurate way in measuring heartrate however, due the direct positioning of TRAC it will greatly improve the accuracy of the reading.

Included in the underside of the device is an Optical heart rate sensor to cross referencing readings. The green LED shows ‘Searching for devices’ and will turn off when connected. The centre panel depresses and clicks and is used to trigger wireless connection and various push gestures. A separate carry case can be used to charge and store a whole sports teams worth of monitors.

_Waterproof medical grade

Aim: To better understand the process of Designing a product made for mass manufacture (injection moulding) Brief: Design a functional polymer ‘widget’ intended to be given away to promote a particular brand or product Main Hurdles: Organising group manufacture and time constraints

SPIRIT LEVEL HOLDER

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DESIGN FOR MANUFACTURE DeWalt Widget _Group and Individual project over 6 weeks This project focused on the mass manufacture of a real-world product between a group of five group members. Each member produced their own widget with one chosen to be manufactured. As a group we chose the spirit level holder as it displayed the greatest potential for injection moulding and had the greatest novelty value.

Once the widget concept was improved the aim was then to design a mould tool which would the allow the widget to be injection moulded. This process began by 3D printing the Design in Nylon and drafting our mould tool CAM design in Blue foam.

The main challenge faced in the CAM phase was to simplify the mould inserts to satisfy the geometry of the design without creating overhangs or negative draft angles.

During the group phase of the project it was important to delegate tasks accordingly and organise the team to achieve the most accurate parts in the shortest time. Accurate machining insured smooth polymer flow and a reduction in flashing.

_Spirit level donor part

Manufacturing Process 8

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BOTTOM MOULD

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TOP MIDDLE INSERT

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CLIP THREAD INSERT

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CLIP BOTTOM INSERT BOTTOM HOUSING MAIN INSERT TOP MOULD

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LOCATION PIN

1 QTY.

ALUMINUM

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MILD STEEL 1 MILD STEEL 1 MILD STEEL

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ALUMINIUM

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SILVER STEEL

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CLIP SIDE INSERT

MILD STEEL

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TOP MIDDLE INSERT PIN

SILVER STEEL

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MILD STEEL

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MILD STEEL

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MILD STEEL 1

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2 PART NAME MATERIAL

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ITEM NO.

BOTTOM HOUSING SIDE INSERT BOTTOM HOUSING WINDOW INSERT

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UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN MILLIMETERS TOLERANCES: 0.25mm LINEAR: 0.1mm ANGULAR: 1 STANDARD: BS8888 PROJECTION: 3RD

SCALE: 1:1.4

DATE: 27/11/2016

SHEET 1/1

SHEET SIZE: A3

GROUP NO: 11

REVISION: 004

TITLE: EXPLODED VIEW OF MOULD ASSEMBLY

MODEL NAME: DEWALT DRILL SPIRIT LEVEL HOLDER

PROJECT: DESIGN AND MANUFACTURING TECHNOLOGY

DRAWN BY: MAX HEARNDEN

LOUGHBOROUGH DESIGN SCHOOL

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A 1

The design for the widget was generated to ensure feasibility of mass manufacture and to produce a promotional item. Small alterations were needed to allow progression to manufacture, such as the fillet at the tip of the clip feet. These changes were realised with the production of the 3D Printed prototype (Second picture from left). The top and bottom mould blocks were then programmed in HSM Works (Solidworks) and tested on blue foam before being milled on the XYZ, CNC milling machine in blue foam and subsequently an Aluminium billet.

Each insert for the mould tool needed to be hand manufactured, this meant each milled surface had to be within 0.1mm of it’s tolerance. Using the surface grinder each face was ground to it’s exact size. This process was repeated on the face sides and edges many times to ensure an exact fit. As a group we ran the mould through the injection moulding machine roughly 10-20 times to fine tune the flow speed, pressure and temperature settings to get the best finished product. Multiple colours were moulded to experiment with flow rate before a yellow and black were combined to create the finished product.

Mass Production

During this project we worked closely with the Materials Department at the University to learn more about the characteristics of polymers and asses the potential problems and goals that need to be met when mass producing a product like our widgets.

Cycle Time Hold time Injection/Fill time

Mould closing

5.020 Seconds

Freeze time

Ejection Insert removal

Target Production

766,920 Seconds 160 Hours/ week 8 Hour maintenance 38.2g polymer/ injection

3,054,549 Total widgets

We were tasked to produce 3 million widgets in 3 months Layout A parallel layout was chosen, instead of a radial one, as it is more realistic to inject polymer from the side. However ideally the polymer would be injected vertically down to assist the filling of the smaller cavities. The sprue legs may have been smaller but this depends on the capability of the injection moulding machine.

_Industry Placement

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ELITE SPORTS PERFORMANCE

_Space planning, Design Visuals and Concept Generation

Tender Process During my time at ESP the biggest tender that we won was for the new Strength and Conditioning suite at the University of Strathclyde in Glasgow. This involved all aspects of our Design capability as a company.

The £31 million Strathclyde Sport Centre is one of the best in the UK. The gym opened in September 2018 and had more than 30,000 visits in the first 5 days. The gym is predominantly used by University Students and Staff but is also open to external sport teams and general users.

“We have without doubt got the best products on the market in appearance and variety of functionality” _Neil Brown, Head of Sport, Strathclyde

The Solution

The starting point for this tender was to understand the Acoustic, Aesthetic and Equipment needs of the client. Brand Guidelines and desired flooring finishes had to be adhered to. A new innovative flooring material was used in this project to seamlessly link the different sections of the facility and provide adequate shock and acoustic dampening.

“Hey, I’m • Facility Design Consultation Jason”

• Acoustic Flooring Concepts • Acoustic Testing • Bespoke Equipment Design • Branding • Space Planning • Installation • Case study

_Original Architectural Drawings and provisional flooring makeup

Conditioning area

Dance Studio Store

Flooring Concept Design

Repeat tests were performed with different flooring materials and combinations at different locations on the first floor of the gym area.

Testing included a 110kg athletic male running on a Treadmill at 10km/h and jump landing off a chair onto the floor. The vibration and noise was assessed by 2 persons at various locations on the ground floor.

The final flooring composition was a combination of A) material stiffness - greater, B) material thickness - less, C) cost of materials less.

GYMflor™ IMPACT provides the ideal solution for protecting and maintaining the subfloor. World leading material technology provides up to 68% reduction in force from impact of dropped weights and dumbbells

Tender Submission Visuals

During the project I produced all of the visuals for the tender including: • Weight plate design • Equipment Design • Storage wall Concepts • Floor markings • Throwing wall layout • Flooring Diagrams • Promotional material • Mirror Spacing • Power socket diagram

“I am really pleased on how things have come to fruition. I believe that we have without doubt managed to gather together the best products on the market and the blend works really well in appearance and variety of functionality” _Neil Brown (Head of Sport, University of Strathclyde)

All renders were produced in 4 days. Therefore, a direct lighting rendering engine was used (Yafaray) to save time.

Pcon Planner and Keyshot were used for the equipment renders

Completed Projects

New layout and equipment for the Manchester City Football Club pre match rooms in the most recent tunnel club and dressing room renovations

Official equipment supplier of Manchester City in partnership with the City Football Group

_Home Gym Design and Installation for a top premier league footballer

Interior Design Renders A few quick renders I produced for my parent’s new Interior Design concept helping to visualise the spacial requirements and basic aesthetics.

A Full 3D model was produced to help make Design decisions during the renovation of the exterior of the house.

Model based on Architects DWG CAD drawing of the new house layout and suggested Aesthetic.

• Pcon Planner • Renderer: Yafaray Direct Lighting • Blender Interior Renders to follow

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+44 (0)7827525313 maxhearnden@gmail.com