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Industrial Design Project

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Design for Manufacture

Time Limited Design


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Surface + Solid Modeling

Extras

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I am a highly motivated and driven individual with a desire to make a positive change to the world in which we live. I aim to achieve this through design. However, If I have learnt one thing in life it is that I cannot achieve these goals by myself. This is why I am looking to join a team of like-minded people with the same aspirations as myself. I am fortunate enough to be able to take a Placement Year in which I would like to offer my creative services and learn more about the attributes and high quality of professional design. This portfolio contains work from my time as a Product Design and Technology Student at Loughborough University.

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VOLUNTEERING

EDUCATION Loughborough University Product Design Technology BSc 2014 - Present

LSRC Committee Media Secretary 2015-Present Action Volunteering Society member

Predicted 2nd Year 2:1

Modules: Design Practice, Design Communication, 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. Shiplake College 2009 – 2014

3D Design Physics Maths (AS) History EPQ

B B C C B

EMPLOYMENT Catering Assistant, July 2016 – Sept 2016 Thomas Franks Ltd, Caversham, Reading Bar Staff Marston's PLC, September 2015 – January 2016 Loughborough

SOFTWARE SKILLS

CONTACT

Gold DofE maxhearnden@hotmail.co.uk


T R A C ONE WEARABLE TECHNOLOGY

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INDIVIDUAL DESIGN PRACTICE Divided

Main features include:

Geometric

Interchangeable strong Medical grade adhesive tabs (1 week).

Faceted

TRAC

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

Sharp

Understanding the form is a very important part of a design. However replicating it is the hardest part. The slightest changes of line weight can throw a the eye in totally the wrong direction.

TRAC is my contribution to the internet of things.

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

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.


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. The second problem with heart-rate monitors and GPS trackers is that most devices are separate and require a strap, watch and a harness.

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.


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 excertion ratings and instantanious power output with up to 25 points per second data output. TRAC is large enough to use an ECG system identical to most chest strap heart rate monitors. This is the most prefered and most accurate way in measuring heartrate for athletes. However I have included a small LED Optical heart rate monitor in the underside of the device for crossreferencing readings. The green LED shows ‘Searching for devices’ and will turn off when conected. The centre pannel depresses and clicks to provide feedback when pressed.


SPIRIT LEVEL HOLDER

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BOTTOM MOULD

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TOP MIDDLE INSERT

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CLIP THREAD INSERT

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MILD STEEL

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CLIP BOTTOM INSERT BOTTOM HOUSING MAIN INSERT TOP MOULD

ALUMINIUM

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LOCATION PIN

SILVER STEEL

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ALUMINUM

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MILD STEEL 1 MILD STEEL 1

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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2 PART NAME MATERIAL

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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 ASSEMBLEY

MODEL NAME: DEWALT DRILL SPIRIT LEVEL HOLDER

PROJECT: DESIGN AND MANUFACTURING TECHNOLOGY

DRAWN BY: ROSE BAINES AND HUGO FRANKLIN

LOUGHBOROUGH DESIGN SCHOOL

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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 curve around the legs. These changes where realised with the production of the 3D Printed prototype (Second picture from left). The mould blocks where then programmed in HSM Works (Solidworks) and tested on blue foam before being milled on the XYZ, CNC machine.

Manufacturing Process 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 finish. Then using the surface grinder each insert 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 between 10-20 times to fine tune the flow speed, pressure and temperature settings to get the best finished product.


Mass Production CYCLE TIME Hold time

We were tasked to produce 3 million widgets in 3 months

Injection/Fill time

5.020 Mould closing

Seconds

Freeze time

Ejection Insert removal

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

3,054,549

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.

total widgets

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.


DESIGN FOR MANUFACTURE

DeWalt Widget Group and Individual project over 6 and 5 weeks respectively. This project focused on the mass manufacture of a real-world product and each member of the group produced their own widget with one chosen to prototype. As a group we chose the DeWalt spirit level as it had the greatest functionality. Brief: To design a functional polymer ‘widget’ intended to be given away to promote a particular brand or product. Once the widget concept was designed the aim was then to design a mould tool which would the allow the widget to be injection moulded. The main challenge faced in the design phase was to think around the individual problems when trying to create specific complex geometry within the mould tool. During the group phase of the project it was important to delegate tasks accordingly and organise the team to achieve the most accurate and functional mould tool possible to reduce flashing and to smooth polymer flow.

Spirit level donor part


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TIME CONSTRAINED DESIGN 9-5 Art Dealer, Inconsistent salary although high end.

Lives in a 5 story Georgian Town house in Kensington with a partner.

Hobbies: Spa Dates, amateur artist, fascinated by nature and natural

“Hey, I’m Jason”

30 mins before set shower time the towel rail will turn on to heat the towels and room.

Habits: Spends too long in the shower and is a ‘clean freak’. Always short of time. Not a morning person. Uses a shower to help him wake up.

Design time 1 Week Brief: Design a product that supports domestic Solar PV systems. It should lead to innovation that makes better use of solar energy, and have a high value aesthetic. Problems: Dehumidifiers don’t actively measure the moisture content in a room. Instead they run continuously. On the other hand extractor fans tend to remove all the heat in the room and never stay on for long enough. Heated towel rails rarely warm towels for when they are needed and can be an easy burn hazard in the bathroom when left on. Both have the potential to use less energy than a PV system can generate. The best way to achieve this is through conectivity and regulation.

Shower is turned on the humidity level will rise. When the temperature in the room reaches a set level the small extractor fan activates to keep the room at a constant temperature. After shower the towels are warm and ready for use. Meanwhile the dehumidifier waits for the temperature to drop to stop the extractor fan, preserve the heat and remove any excess moisture from the air. This time utilises maximum daylight levels. After an hour from the moment the extractor fan turned off the towel rail will turn off and let the dehumidifier run until the room has returned to a appropriate level of humidity.


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COMPUTING FOR DESIGN The main aim of this design was to challenge my complex surface modelling skills in PTC’s Creo Parametric. It was also necessary to make the bottle’s features manufacturable. This was done by adding rounds and chamfers to the parts that needed it. After the surface model was complete I then needed to create a solid model with a female screw head to match the mechanical components of the spray assembly. I used the surface model as a skeleton to copy the geometry across and then formed the rest of the parts in the assembly. After a full merge and solidify it was then easy to render in Keyshot.

CAD: Creo Parametric Renderings: Keyshot 6

Parts: 13 One merged surface Two-part modelling


OTHER PROJECTS Electronics for Design has taught me the fundamentals of electronics in design and have broadened my knowledge in integrated systems within products. Each project requires the capability to learn and work independently or as a group. I have also become familiar with C-Programming and Electronic CAD systems and how they can be applied in the design of products and systems. I am also in the process of designing an embedded microcontroller system to sense and detect types of ferrous metals in a laboratory environment.

User Experience Design is an expanding area of design and was one of my chosen modules. The subjects coved looked into the areas of interactive product design, persona and scenario based design techniques, user interface design, usability testing and investigating the user centred design process. I have used Axure to prototype my own, ‘O2’ inspired, crowd funding App for multiple screen dimentions. I have also used my videography skills to create a video prototype into our ‘E.on Flatmate’ App that was developed by my group.

Mechanics for Design gives me a solid understanding of civil and mechanical engineering principals and it is one of my strongest academic areas. I am currently looking further at the mechanics of solids, including combined bending and direct stress, shear force and bending moments, shear and torsion, momentum, impulse and impact. These insights are being applied in a design task to perform full mechanical analysis and the manufacture of a fully functioning squash ball throwing machine.

Hairbrush Re-design. This design project required an individual and group solution to the problem of re-designing the Mark Hill Hot Air Brush. This product had been returned to the Boots in Loughborough and it was our task to find problems with the design, both internal and external. The main focus for our design was increasing the functionality of the product and improving the design ergonomically. We also took into consideration the sustainability of the product and the product lifecyle. A Design in Enterprise aproach was also used.


I have been a rower since the age of 13 and it has taught me a lot about myself and other people in and around a pressured environment. I have explored my physical and mental limits and I have learnt how to deal with success and failure. All the experience I have helps me massively in my, sometimes stressful, time as a Design student. It allows me to use my time effectively and keep a clear mind when dealing with design tasks and overcoming problems. During my time at University I have contributed to a rapidly expanding Boat Club within the role of Media Secretary and Coach. This is voluntary work and is my way of giving back to the Sport that has offered me so much. I have also used my design skills to help make posters and leaflets for the club and to aid recruitment.


CONTACT

maxhearnden@hotmail.co.uk

Max Hearnden Product Design Portfolio 2017  

I am a passionate Designer and Sportsman currently applying for a 12 month placement starting July - September.

Max Hearnden Product Design Portfolio 2017  

I am a passionate Designer and Sportsman currently applying for a 12 month placement starting July - September.

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