Mark Chester Digitial Designer DESIGN PORTFOLIO - 2019
Private & Confidential - All Rights Reserved
Introduction... Industry 4.0 is revolutionising the methods in which industry design and manufacture products. As a designer, I am required to constantly learn, adopt and challenge these methods to increase innovation. Recognising the need to further develop my skills, I challenged myself to study an MSc in Industrial Digitalisation. This has required good time management, creativity, motivation and determination; especially when working independently on live projects or in partnership with large organisations.
Contents... 1. Design a Virtual Reality Headset
3. Masters Research Project
5. Redesign the Safety Trainer
2. Exploring Generative Design
4. Infant Lower Limb Prosthetic
6. Playscheme - Playground Designer
7. Design a Solution to Golf Wastage
9. Autodesk Design for Automotive
11. Major Project - Redesign a British Icon
8. Autodesk Design for Robotics
10. Minor Project - Extrasensory
12. Content Creation - Airgineers
1. Design a Virtual Reality Headset...
Skills
Making objects in CAD software can lead to manufacture with additive or subtractive methods but there are more uses for the data than these alone. Any object created in 3D may then be viewed in specialist stereo viewing equipment commonly known as Virtual Reality. Create and manufacture a Virtual or Augmented reality viewer headset that is made for your face and your own mobile device.
Intergrated generatively designed structures provide significant reductions in weight, enabling the user to wear the headset effortlessy.
Bespoke 3d printed padding and an integrated air circulation system provides long lasting comfort, allowing the headset to be worn for longer periods of time.
Mixed Reality Mix3D reality headsets are designed with the user in mind. Each headset is specifically generated to fit your head, utilising 3D scanning and additive manufacturing technologies. Each design is different, customised to suit your own personal style. We believe mixed reality is the future, enabling you to switch between realities quickly to focus on the project in hand.
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2. Exploring Generative Design
Skills
Generative design utilises artificial intelligent algorithms and cloud computing to produce multiple design outcomes whilst meeting set requirements. Introduced into Autodesk Fusion 360 in 2018, only ten universities across the UK were allowed special access. Over the last year I have become competent in Generative Design Simulations, applying it to multiple products from scooters to benches.
On average a scooter weighs around 5 Kilograms, making this mode of transport unappealing to many commuters. Utilising generative design I looked to reduce the overall weight to 3.5 Kilograms.
Starting in Fusion 360, I created a digital twin of each component in order to simplify the manufacturing process. The complete design was created from scratch utilising advance 3D printing technologies and traditional methods of production.
Which side would you sit on? Designed as a social study to investigate into consumer acceptance, this bench was identified by the President of Autodesk Fusion 360 in America. Currently the bench is being casted using macro additive manufacturing technologies.
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3. Sponsored Masters Research Project
Skills
A study conducted in 2015 analysed all injuries at Wimbledon between 2003 and 2012. This research identified that 47% to 49% of injuries between females and males were in the lower limbs. This research aims to investigate how advanced digital technologies could reduce the risk of injuries within players, by contributing towards the development and innovation of footwear.
Pressure sensors identified high levels of pressure exerted at the heel, front of foot and toe up to 250 KPA during landing which is then distributed across the foot. Areas of high force were specifically targeted from the pressure maps collected. Video footage also identified regions which required preserving.
Increasing ankle stability Initial forces acquired within the initial data collection phase were imported into a Generative simulation. Results of the simulation identified areas which require additional material to aid the stability of the foot. Structures identified within this simulation could be easily implemented into existing footwear designs.
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4. Infant Lower Limb Prosthetic Between the ages of 1-3 a child’s development is crucial, as early as 3- 5 months a baby will begin to reach out and grab objects as their muscles start to develop. Key milestones such as learning to crawl between 9 – 12 months can be extremely difficult for a child with one hand. Furthermore, children of this age grow constantly making current NHS prosthetics redundant in a matter of weeks. This project investigates how 3D printing technology can be implemented within the NHS to rapidly produce custom fit infant prosthetics.
Consisting of 3 main parts, the prosthetic is designed to be modular. This allows the parent or child to freely switch between arms and attachments to suit different occasions and situations.
Skills
Intuitive Strap design allowing the user to easily grip on to objects. Strap can be easily changed if broken or worn.
Interchangable Arm to Socket Connection for multiple arms - Easy for the user to slip and twist on.
Gentle and Rounded aesthetics to make the prosthetic more suitable for children.
Hinged Hand to allow the user to grip onto varying object sizes.
Customisable Arm design, personalised bespoke to the user Flexible Strap to allow the user to obtain a firm grasp of most objects Multiple Printed Part - Modular Concept Benefits - Customisable, Adaptable to multiple situations and requirements, Interchangable Straps, Easily built by user, ‘Lego of Prosthetics’ providing positive association, Less chance of print failure, Break away attachment in case of accident. Considerations - Manufacturing includes multiple printed partfiles and an assembly, slower production speeds. Parts more likely to break.
Interchangable attachments, user can change to suit their requirements
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5. Redesign the Safety Trainer
Skills
Scal3D investigates how new technologies can be utilised within the footwear sector to create personalised safety shoes tailored to the user’s requirements. Furthermore, how applying additive manufacturing and 3D scanning techniques can reduce over production of shoes and reduce wastage within the footwear industry, as currently over 415 million pairs are disposed of on an annual basis.
The overall form of the shoe was developed within Fusion 360 using complex T Spline and surface modelling techniques.
3D PRINTED SAFETY TRAINERS
3D Printing technologies played a vital role in rapid prototyping concepts at various scales to achieve the perfect form and aesthetics.
Each foot is different... Safety footwear is a requirement within a range of industries; however, many users find safety shoes bulky and unappealing. Scal3D looks to change the stigma around safety footwear by providing a lightweight and stylish shoe which is fit for purpose. Each shoe is designed to perfectly fit the users individual foot, utilising 3D scanning and additive manufacturing technologies.
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6. Playscheme - Playground Designer
Skills
Playscheme is a family-run company with a wonderful reputation with over 20 years' experience in creating inspiring bespoke outdoor play areas for schools, nurseries and public places. They’re one of the UK's few true bespoke specialists and have vast experience of designing, manufacturing and installing custom-made environments that are imaginative, exhilarating and educational.
Starting in Google Sketchup, each individual component was drawn up and costed, before being sent to the workshop for manufacture and then the site team for installation.
Each playground is created different with an underlying theme. The transformation of Hornsea Freeport started as a £250,000 scheme which was later cut down to £100,000 due to investors pulling out.
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Creators of Outdoor Play Environments...
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7. Design a Solution to Golf Waste
Skills
Each year, thousands of golf clubs are sent to landfill due to the complex materials in which companies choose to manufacture such as Carbon Fibre. Currently there is no effective way of recycling golf shafts and until manufacturers choose more sustainable materials, more clubs will be thrown away. This project investigates products which can upcycle golf clubs, giving them a new lease of life.
To decrease 3D printing production times, small couplers allow the shafts to push fit into the connectors. These couplers can be printed quickly increasing manufacturing speeds. Allowing a range of Golf clubs to be re used. Connectors can be standardised and printed on mass in a range of styles and colours.
Golf clubs can be made fun. A variety of connectors would allow users of all age groups to create simple structures, through intuitive and cost-effective 3D printed parts. These simple frames can be transformed into a den with the addition of beds sheets and other decorative materials. There are further opportunities to transform these structures into tents or dens for children and pets through manufactured sheets.
Providing Products within a Circular Economy Practice makes perfect. A combination of Golf club shafts and 3D printed connectors creates a strong light weight structure which can be developed into a range of shapes. Shafts can be cut down to a variety of sizes to produce targets both big and small to suite the user’s requirements. The addition of Ripstop Nylon creates a durable and weatherproof product which could be used both in and outdoors.
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Skills
8. Autodesk Design for Robotics Imagine the home of 2025. How will robots assist you with everyday tasks in and around the house? The field of robotics is advancing quickly to support our busy lives proving that robots are fast becoming part of our daily reality. Autodesk and GE AppliancesÂŽ are looking for a few innovative robots before 2025 that will help run a modern home. Design the robot of the future today in the Autodesk Design for Robotics Challenge.
Move is a home transportation robot which connects the internet of things to the world of things. Its primary function is to move objects around the house without the owner having to lift a finger.
Move is a device which could be easily developed into existing or new homes. It could also be integrated into existing GE Appliances products creating a new range of home appliances.
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9. Autodesk Design for Automotive - Winner Autodesk has challenged you to design the “Race Car of the Future” using Autodesk®Fusion 360™ software. Put your automotive skills in gear considering aerodynamics, driver safety, aesthetics and brand identity for your design and your skills could help to define a whole new class of race car!
Using Hydrogen fuel cells, the design focuses on how Formula 1 needs to become more sustainable in order to preserve the sport for future generations
The centreless wheels are driven by electric motors, each wheel incorporates an advanced braking system that feeds enegry back into the onboard battery.
Skills
The Future of Formula 1... This concept Formula 1 car was designed for the year 2030, it’s main focus is to make the sport more sustainable through the use of alternative fuel sources. The design was one of four thousand enteries worldwide and was judged by the head designer at Mercedes AMG.
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10. Minor Project - Extrasensory
Skills
Extrasensory allows you to connect the world of things to the internet of things. From doors to draws, simply place the device wherever you need to monitor. Perhaps you’re going on holiday, and want to make sure that the contents of your bedside cabinet are safe. Extrasensory will detect any movement and notify your phone if and when the cabinet has been opened or an object has been moved.
Extrasensory is made up from a Iot Board, Sensor and Battery pack. The sensor detects when the device has been moved in any direction and notifies the user.
This device is available in both Wifi and GSM versions allowing you to place the product in a remote location to monitor outbuildings or sheds.
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Skills
11. Major Project - Redesign a British Icon The British icon I chose to redesign was the Land Rover Defender. As one of the longest production lines of all time, spanning 68 years, the Defender is a true British Icon recognised all around the world. Unfortunately Land Rover stopped the production of its Defender in January 2016, with rumours of a replacement in 2019. My proposal was to redesign the Land Rover Defender, keeping true to its farming background. The design will be a limited edition model which celebrates the hundreds of thousands of Defenders still on the road today.
The design is a combination of what Land Rover was in the past and what it looks to be in the future, keeping up to date with the current range of Land Rovers, whilst maintaining its farming heritage.
The concept works both in the countryside and on the road. Staying true to its primary use as a utility vehicle, with plenty of load space and high clearance for going off road.
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12. Content Design - Airgineers
Skills
Airgineers is a STEM challenge for secondary school aged students who will need to design, build and learn to fly their own radio controlled quadcopter, often referred to as a drone. On their quest to become Airgineers UK Champions, teams will compete in two different classes, Micro and 3S.
I created a series of videos tutorials to guide users through the process of designing a drone in Fusion 360. The tutorials are aimed at complete novices, so even if you have never used Fusion 360 you will be able to follow the step-by-step guides and learn all the steps needed to then go on and design your own micro drone frame.
As well as learning how to design in Fusion 360, the videos will also show you how to estimate the weight of your frame before printing, simulate the stresses and loads to find weak points in the design and add other components like the motors and flight controller. You will also be able to add decals to the design, export high-quality renders and create animations.
Inspiring the next generation... In addition to developing my own skills as a designer, I think it’s important to also help the next generation of designers and engineers. Across the last two years, I have taught over 1000 students in primary and secondary schools, as well as multiple unversities including Imperial College London and Glasgow School of Art.
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Created by Mark Chester Digital Designer markchesterdesign.com mchesterdesign
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