EARL ULGES ORTFOLIO
PRODUCT DESIGN.
PORTABLE LIGHTWEIGHT OXYGEN CONCENTRATOR
OXY
This project was shortlisted for Loughborough Enterprise design award and was also featured on ‘Favourite disability designs from 2017’s graduates’ on Crack it design website by Demand.
RESEARCH . In the UK, approximately 10,000 people are newly diagnosed with a lung disease every week. Lung diseases could happen to anyone at any age. People with respiratory diseases carry around oxygen tanks with them. However, oxygen tanks are heavy, need constants refilling and maintenance hence why the oxygen concentrator is a better alternative. Patients with respiratory diseases are embarrassed to carry oxygen tanks or concentrator around. They feel socially awkward to carry around the oxygen tanks, and it also limits their daily active activities.
USER INSIGHTS . Oxygen therapy is the medical solution for patients with lung diseases. To fully understand their pain points and the market really well, a combination of primary and secondary researches are needed to identify design gaps.
PROBLEMS
NEEDS
Loud noises
Quiet machine noises
Social awkardness
Discrete design
Short battery lives
Long lasting battery
Heavy weight
Light weight
SOLUTION . This portable oxygen concentrator concept design weighs just around 1.5 kg, containing long-lasting battery life, simple user interface and functionality focused. The design also features an integrated oximeter and heart rate sensor with Bluetooth connection to smart devices to help reassure and track the patient’s use of oxygen.
CONCEPTUALISATION .
Various concept are explored to identify the potential design for functional and aesthetics purposes. The design is explored in many various aspects. Not only just forms and shape that could potentially be made more appealing than existing products in the market, but also explore possible functionalities that can be achieved with the speciďŹ c shapes.
OXY
PROTOTYPES . USER TESTING . ITERATIONS .
“ Why prototype something if it will just be sitting there and do nothing? ” Externally The aim of prototyping is to use it for testing your concept at different levels of fidelity. The prototyping stages range from blue foam ( testing out the initial form of the design) up to a 3D printed model (that was used to evaluate the product feasibilities with the users). Internally Not only the externality of the machine is critical to analyse, but also the internals. The primary purpose of this design is to have a long-lasting battery and a technology that could reduce the size of the oxygen concentrator and weigh a lot less. Therefore, it was crucial to test out the internal circuit, and the main functionality of the oxygen concentrator was to be understood. The internal was prototyped mainly by software coding using Arduino and hardware building. The components are chosen specially for patients that require a low LPM (litre per minute) continuous oxygen flow whom just started having respiratory diseases. The design also included an oximeter so that the user can monitor their heart rate and oxygen level by using a new oximeter technology that can be found in smartphones and health trackers. This sensor has not been intergrated anywhere medically for respiratory equipments. Final 3D printed parts after various design iterations
ASKING THE PROFESSIONALS .
Great Insights usually comes from people who have the needs to use the product regularly.
User insights are gained from this stage of design development. Various participants are chosen to test out and gain their qualitative feedback from the design. This then is later use to iterate the design and improve it accordingly.
VICTORIA
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65 years old, London Suffer from bronchitis and asthma. The participant needs to always carry around with her the asthma inhaler and was on oxygen therapy for a short while. She lives an active lifestyle and does not like to stop and be at home. She likes the simple, interaction and feel like it is highly useful, applicable with the diseasesince to carry out any sort of testing, mainly the participants needs to go to the hospital .
LISA . 71 years old, Nottingham Suffer from COPD. The user felt like the machine is compact, small and highly portable! The participant did not feel like it disturb her daily routine. It is a lot easier to manage comparing to the existing one the participant has been using. She suggested that a cut out from the battery section should also be considered since it would be a good indicator of where to pull the battery out from.
SARAH . 25 years old, London Respiratory nurse at St George’s hospital. A lot of knowledge was gained from the nurse about how various patients reacts, get diagnosed and how oxygen is prescribed out. One feature that stood out was the Bluetooth tracking feature. As a nurse, it is hard to get an accurate tracking and reliable answers from the patients about how much oxygen they have been using.
These are the final prototypes. 3D printed model for aesthetics and the other one is for functionality internally.
OXY FINAL DESIGN
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2LPM flowrate compact oxygen concentrator for patients who started having lung diseases.
Weighs only around 2 kg with long-lasting battery power.
Easy access and storage to the nasal cannula just by pressing the button.
The design includes heart rate sensor, oximeter and Bluetooth to transfer patients’ readings.
Lid Push button Nasal cannula storage space Oxygen nozzle Side pins Air filter Oxygen storage tank Zeolite sieve bed Power button LED battery indicator Air filter cover Air pump
Side parts Battery Internal holders Battery casing OLED screen PCB Oximeter sensor Buttons
E X P L O D E D V I E W
SCENARIO BOARD .
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. 2.Press the power button to switch on the machine 3.The machine starts making oxygen by drawing in ambient air through air filter 4.Unravel the nasal cannula to use 5.The battery can be remove and change accordingly INTERNAL MECHANISM .
2. SOLENOID VALVE 1 De-pressurised the system and release out the trapped nitrogen gas in the chamber.
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. 7.To measure heart rate/ oxygen level, press the button to activate the sensor 8.Place your finger tip onto the sensor to measure. User’s data can be sent to mobile phones via bluetooth 9.When the machine is not in use, wrapped the nasal cannula back in the slot 6 Or the machine can be directly charge from the power socket
4. SOLENOID VALVE 2 Control the gas pressure and system timings
OXYGEN OUT
3. ZEOLITES 5A IN SIEVE BED Separates out the different gas molecules allowing oxygen molecules to pass through and due to pressure, trapping nirtogen.
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NITROGEN & PRESSURE
1 The concentrator can be carried using a shoulder strap or put in a bag
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Zeolites
AIR IN 1. The air is drawn in using micro air pump.
Storage tank
5. OXYGEN OUTPUT Oxygen output is release using pulse dose system triggered by breathing.
PROMOTIONAL PEN HOLDER WIDGET
COPIC
THE UNIQUENESS .
This project is a truly unique project since it mainly emphasises on the manufacturing side of the product. The aim of this project is to create promotional give away widgets for a specific brand as a marketing product through an injection moulding process. The widget must be low in monetary value but still appeal to customers. In a team of 6, we all came up with an idea. The Copic idea was chosen to be taken forward for manufacturing due to the feasibility and the bold identity of the brand. Copic is a brand that is close to all designers’ hearts hence it being the final decision.
DESIGN PURPOSES . A common issue that artists and designers usually face is the fact that the markers clutter the desk. This Copic marker holder would be a handy promotional widget that is designed to reduce the clutter on the desk by only keeping their main markers in hand. This enhances the user’s workflow and organisation of the working space.
3 Copic marker holder Empty spaces shows marker shape Dimples to fold the pens in position
The simple design acts as a visual standpoint resembling a marker from a side view.
Three parts assembly Stability from the overall shape
Colour scheme
MANUFACTURING PROCESS .
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3D PRINT A quick prototype is printed so the overall form can be analysed before committing to manufacturing the mould.
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LATHE Series of pins and bars are made by turning mild steel rods to a particular geometry for holding the inserts and blocks in place for the injection.
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FINISHING All the parts were polished up by hands with emery cloth and wet & dry paper for better mould assembly and surface quality.
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FOAM BLOCK A prototype foam mould block was made to test if the tool paths were correct. Mistakes were resolved, and engineer drawings were updated.
MILLING The main inserts were made manually on the milling machine. Perfect tolerancing had to be achieved at this process for mould assembly.
ASSEMBLY All the inserts, pins and mould blocks were tightly assembled and locked together, ready for the final injection moulding process.
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CNC MILLED After all the CNC tool parts were perfected, aluminium mould blocks were CNC milled along with three other inserts.
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SURFACE GRIND The grinding machine was used to achieve the precise tolerance finishes especially when it could not be achieved by the milling machine.
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INJECTION Finally, HDPE plastic was injected into the mould to create the widget. Gate size was altered to prevent short shots and allow even filling.
PROBLEMS & SOLUTIONS . Tolerancing was one of the main problems that we faced when it came to manufacturing the inserts. Human and machine errors build up through the manufacturing of inserts creating chain tolerance, building up, and causing the assembly to become rather troublesome. The main insert was created several times because the dimension of the piece was slightly too small causing it to not fit properly with other inserts. This would cause flashing when the plastic is injected. Teamwork was the greatest asset in this project. We helped each other by delegating different tasks to suit specific skillset and maximising the efficiency of our team. We helped each other figure out the problem and try out various solutions. For example for the main insert tolerance, we ended up milling down and leaving some depth for it to get grind down for highest precision.
COPIC MOULD DESIGN IN CAD .
. SUB INSERT 1
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. 2 X 4MM PINS
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. 3 X 4MM PINS
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Place the smallest insert into the bottom mould half first.
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These pins are used to lock in the 3 inserts and the bottom mould half in place.
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Push these through the big pins to be a locator and the upper mould half.
. MAIN INSERT
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. PLATE INSERT
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. TOP MOULD HALF
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Place the main insert into the mould aperture ensuring the 14 mm holes are facing out.
Push the plate down, ensuring the plate is tightly snugged in around the edges.
Put in the top half and make sure that all the pins and the inserts are aligned.
. SUB INSERT 2
Place another sub insert upside down to create a small gap between the parts.
. 3 X 12MM PINS
Push the pins into the main insert but also making sure that the 4 mm holes aligned.
. 2 X LOCATOR PINS
Finally, the pins are pushed into the holes to secure the overall assembly of the mould.
The mould tool is designed in CAD through Creo. Tooling path was also developed before it gets manufactured. Pressure and plastic analysis were also done to come up with the best design of sprue gates and injection position. Plastic advisor also illustrates the possible warping and the in the consistency of the plastic that could occur with different wall thickness. A calculation also determined that for each widget, 16.03g of HDPE plastic is needed to create one widget which fits well into the initial set budget.
THE MOULD . Back Insert Mild Steel Milled
Bottom Mould Half Aluminium CNC Machined
Plated Insert Mild Steel Hand Tooled & Surface Grinded
Top Mould Half Aluminium CNC Machined
3 x 14 mm Aperture Inserts
3x Aperture Insert Locator Pins
Main Insert Mild Steel Milled & Surface Grinded
2x Insert Locator Pins
2x Sub inserts Mild Steel Milled
2x Mould Block Locator Pins
Mild Steel Rod Lathed
MASS MANUFACTURING . INJECTION LAYOUT . MANUFACTURING CYCLE .
Injection
1.1
Holding
0.7
Cooling
0.2 x 2
Ejection
2.75
Opening
1
Insert removing
3.48
Colour change
0.5
Closing
0.2
Cycle time: 9.93 576,000 / 9.93s = 58,006 59006 x 4 = 232,024 (per week) 232,024 x 13 weeks =
3,016,314 Widgets
BLOOM
GAMIFICATION AND BEHAVIOURAL CHANGING ENCOURAGER
1 S ER EP US ST 0
30
BLOOM
CORE FUNCTIONALITIES . Set aim steps no.
Unlock
Bloom is an innovative way to encourage walking and decrease snacking at the oďŹƒce through team building and game mechanics strategy. Through a simple design, Bloom will help create enthusiasm among colleagues to become healthier in a rewarding way.
No. of users
Lock
On / O
Internal jar
Main screen
Movable robotic petals Buttons Pedometer slots Pedometer
PRIMARY RESEARCH .
VIRAPAN.P Age:56 CEO of TICON industrial co.,ltd, Works in Thailand Work from 9:00-17:30 weekday
PROTOTYPE .
" I try to walk around after sitting at the computer for too long, go meet colleagues at their desks instead of calling them over; but since I'm the CEO, people usually come to see me in my office." " If I'm in lots of meetings, I don’t get to move around at all." " When someone brings in home bakes influence me to try their bakery goods. " " I do sit at my desk all day unless I have meetings. "
ANNE.K Age:26 Product Management executive at TCC Global Works in London Work from 9:00-17:00 weekday
" I don't take any breaks to stretch and walk around at all. " " I walk around either at lunch/ tea breaks or to go to talk to my colleagues in another team. " " I snack on sweets most of the time, chocolate, candy, etc.
SECONDARY RESEARCH . Gained statistics, scope of the brief, key areas and researches
Many adults in the UK spend more than 7 hours a day sitting or lying. (Choices, 2016)
Studies have linked excessive sitting with being overweight and obese, type 2 diabetes, some types of cancer, and early death.
Office workers are most likely to get hungry again and snack more, with 35% reaching for treats, compared to 14% of non-office workers.
51% of 1947 women confessed to eating between 650 and 750 calories worth of snacks each day with 87% regularly squirrelling treats away at their desk.
(Choices, 2016)
(Payne and Bains, 2013).
(James, 2012)
Payne, E. and Bains, I. (2013) Office snacking causes women to pile on over 6lbs - or a WHOLE dress size - a year (and men arenʼt much better). Available at: Choices, N. (2016) Why we should sit less. Available at: http://www.nhs.uk/Livewell/fitness/Pages/sitting-and-sedentary-behaviour-are-bad-for-your-health.aspx (Accessed: 3 February 2017). In-text citations: (Choices, 2016) http://www.dailymail.co.uk/health/article-2280994/Office-snacking-causes-women-pile-6lbs--WHOLE-dress-size--year-men-arent-better.html#ixzz4Xa9kgBe2 (Accessed: 3 February 2017). In-text citations: (Payne and Bains, 2013). James, G. (2012) How to avoid office snack weight gain. Available at: http://www.huffingtonpost.co.uk/2012/02/02/how-to-avoid-office-snack-weight-gain_n_1249872.html (Accessed: 8 February 2017). In-text citations:(James, 2012)
USER
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TASK
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- Age 20-60 - White collar - Working in big firm - Busy, urban and fast pace life - Sociable, friendly, caring, inclusive - Promote physical activity - Reduce unhealthy eating in office - Build Teamwork and relationship in workplace - Stress relieve and productivity increase - Game mechanism REWARDING
ENVIRONMENT
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- Offices - Urban & Indoor - Digitalised and connected workplace
This design brief was an intense, one week project that allows me to explore all the design aspects from the very start till the very end.
BLOOM CONCEPTUALISATION
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SCENARIOS .
1. Press the on the button to switch on the device. 2. Look at the display and follow the following instructions: - Set the number of users (maximum 8 people) by pressing the user button. - ConďŹ gure the target number of steps for the team as an aim. - Press unlock to open Bloom up. 3. Take out the internal jar, unscrew the lid at the bottom and ďŹ ll it with sweets, biscuits, chocolate, etc. 4. Put the jar back on the device and press lock. Bloom will lock up the sweets until the aimed number of steps is reached. 5. Each user pulls out a pedometer and carries it around all day to track their step count. 6. At the end of the day, slot the pedometer back into Bloom. Bloom will add up the total group step counts at the end of each day and display it on the main screen. Pull out the pedometer again the next day and repeat the cycle. 7. When the target is met, the pedometer will buzz, the display on Bloom and the pedometer will say 'Unlock your treats!'. 8. Press unlock button, take out the internal jar and enjoy your well-deserved snack time with your team!
THE MAGICAL PLACEMENT YEAR
DISNEY
PLACEMENT YEAR AT DISNEY . “It's kind of fun to do the impossible”- Walt Disney I was lucky enough to experience how to make the impossible, possible. During my placement year in London as a product development intern at the Walt Disney company, I learnt how the world-leading company operates using multiple business strategies driven by numerous amount of creativity. In-depth, I explored the world of licensing and worked with different markets across Europe, Middle East and Africa where the needs among the various cultures and restrictions within each market are demonstrated, especially the emerging markets. I worked mainly for 3 teams during my year at Disney.
Product development
I developed various product concept that is plausible in each emerging market. With emerging market like Africa, the product that will be developed must be low budget. With that in mind, the product still needs to keep the Disney brand standard. I had to figure out the right balance between the two and create something unique for the licensee.
Sales (Strikeforce) team
I got the chance to manage a product brainstorming event within the company and use my inner creativity to create product mock-ups with various Disney, Lucas and Marvel characters to inspire people internally and externally, like licensees, to see the potential products to be set up in their local markets. I also initiated the first sales team newspaper to be distributed around so that people can have more knowledge of Disney’s new properties.
Publishing The UK is a country where books and novelty are still hugely available to everyone. Within my role, I had to explore the streets of London and go to various trade fairs to look at the current books publishing and toys trends. I then use those trends and update other publishers in the emerging markets and inspire them to use the Disney properties that they have on hand to create new products in their local market. This was such an inspiring year. I was exposed to so many inspiring people and learn how the most magical company takes the creativity and bring it to real life.
DR. STRANGE .
This was a particular project that stood out. This was the concept development artwork I did Doctor Strange the movie. The brief was to design apparels and accessories for young adults. My work was later, not only approved by Disney but also approved by Marvel headquarters in New York. The concepts were used to inspire many well-known clothing brands globally like H&M, Primark, etc., so Disney can potentially create a clothing line through with them to promote the movie and generate more income through licensing.
“The greatest gift we an recieve is to have the chance, just once in our lives to make a difference.”- Stephen Strange
DISNEY BACK TO SCHOOL
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This concept was based on 'back to school' theme for young kids. The movie came out in the summer holiday when all the small kids would later go back to school. Therefore it was an excellent opportunity to create and sell something to do with schooling, for example, backpacks, lunch boxes, etc.
The Jungle book concept was aimed at older middle school kids. The artwork for this movie is a lot more sophisticated, and as it is such a Disney classic, this was the perfect opportunity to create something with lots of jungle theme patterns and use the main characters to make the products iconic to consumers.
KELLOGS X DISNEY .
THE PERCEPTION .
When it comes to FMCG and food, there is a perception that when Disney is branded onto a food package, this food is unhealthy. This was mainly to do with the previous packaging design that uses bold, wacky colours with big bold characters on the boxes. Although these designs attract children, it does not persuade the parents to get the cereal. The brief for this packaging design was to create a new perception for cereals and make them seems healthier. Thus, the brand will enhance customers attraction by using Disney characters. The designs should persuade both the parents and young children. The ďŹ nal aim of this is to try and remove this stigma relating to unhealthy cereals and Disney.
IT’S ME PEARL PULGES
P FOR
EXPERIENCE .
LET'S TALK asama.pulges@gmail.com
Please e-mail for more detailed experiences and achievements on my CV. 2019 - present
UX Designer Siam Commercial Bank, Thailand
#2
2017 - 2018
MSc Entrepreneurship and managment University of Bath, UK
#1
2013 - 2017
BSc (Hons) Product design and technology 2:1 Loughborough University, UK
2015 - 2016
Product development intern The Walt Disney company, UK
LANGUAGES . ENGLISH
THAI
FRENCH
SKILLS . Photoshop
Axure
Illustrator
Balsamiq
InDesign
Sketch
Microsoft suites
Invision
Creo
Overflow
Keyshot Arduino
LOVE . PHOTOGRAPHY SOCIALISING TRAVELLING COOKING DRAWING UKULELE AIKIDO
JAPANESE