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SAMUEL THOMAS MOSELEY +44 (0) 7969510323

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Contents Audi R8 Alloy Wheel Self Initiated Project

2012 Olympic’sUK Sport Competition Brief

FORD Transit Climate Outlet Adapter

FORD Transit Climate Assembly Fixture

Audi R8 Alloy Wheel Self Initiated Project

SOLIDWORKS - SURFACE MODELING This image is part of a series of rendering’s from a Parasolid model I have created of the Audi R8 alloy wheel. The model was originally produced with Solidworks and rendered with Keyshot 2.1. I chose to use the Keyshot rendering package as I felt it has a lot more versatility and created a more realistic outcome. I made the model in my spare time to improve the way I approach future projects. Using this process of reverse engineering it has helped me break down existing products and visualize the surfacing techniques required to produce and ultimately manufacture products. In addition to this, I also animated the model. The model shows the acceleration from stationary to 300RPM to and then decelerating back to a stationary position. This can be seen at; Materials that are Alloy Wheel Tyre Brake Disc Disc Caliper


used in the rendering; > Aluminium > Rubber > Brushed Aluminum > Anodized Metallic Paint

Samuel Thomas Moseley (BSc Hons) Product Design Bournemouth University

Audi R8 Alloy Wheel Self Initiated Project

AUDI R8 - Key Statistics “Quattro ® was the world’s first permanent four wheel drive system and still leads the way. Up to 90% of the engine’s power is pushed to the rear wheels, while Quattro kicks in and distributes it precisely when and where you need it. Having become synonymous with the Audi brand, Quattro is available on every model in the range. “ “Up to 90% of the power is pushed to the rear wheels, However it can vary between 10 - 13 %” “2.65m Wheel Base” “Weight distribution 44:56 front to rear” “Three drivers from three different disciplines tested the Audi R8’s handling to the limit. Each had their own idea of perfection. Each helped us strive to achieve it. Based on their feedback, for example, we lengthened the wheelbase to provide high-speed stability and incredible traction.”

All statistics taken from


Samuel Thomas Moseley (BSc Hons) Product Design Bournemouth University


Samuel Thomas Moseley (BSc Hons) Product Design Bournemouth University

2012 Olympic’s - UK Sport

Competition Brief

Brief At the Olympic Games in 2004, there was less than half a second in time difference between winning and losing the gold medal in Kelly Homes’ 800m race, the men’s coxless fours win, Chris Hoy’s victory in the 1km time trial and the men’s 4x100m final put together. In 2008 there was less than 0.2 seconds between Rebecca Adlington’s 400m freestyle win and David Weirs 800m wheelchair racing Gold medals. With gold medals won and lost within such tiny margins, innovation really can make a difference to the success of British athletes. UK Sport is charged with leading sport in the UK to World Class Success. To achieve this, UK Sport works to deliver medals at the Olympic and Paralympic Games.

IDEa - Pre-Cooling “Exercise causes your body temperature to rise, the harder you work the more rapid this rise will be. However, regardless of training state or climate, it is apparent that there is a critical limit at which point athletes are forced to either reduce exercise intensity or risk heat-related illness. The amount of heat stored in the body will limit the duration of exercise at a given intensity, it obviously makes sense to start exercising with as cool a body temperature as possible. In essence, the purpose of body cooling techniques is to increase the margin between your starting Tc and the Tc that will force you to reduce your pace.”

Solution Through extensive research I have found that it is possible, by surrounding the body in cool air to reduce the body’s Temperature and maximise the margins. By using compressed gas canisters; The jacket eliminates the restrictive movement which is implemented by the liquid cooled vest systems. The jacket doesn’t need to be frozen prior to the event. The jacket can be used for a prolonged period of time, which means that members of the Great Britain team can use the vests consecutively.


Samuel Thomas Moseley (BSc Hons) Product Design Bournemouth University

2012 Olympic’s - UK Sport Competition Brief

Material and Fabric The jacket will be made from 3 different materials; The outer surface of the jacket will be made from a lightweight but strong PVC. This is because the jacket needs to be light but the panels of the jacket need to be airtight when hot wielded. The surface that will be in contact with the skin will be a blend of polyester, nylon, cotton and Lycra®. The blend will ensure that the skin can breathe and relay any moisture on the skin to the air surrounding. The two internal surfaces will be made MPET (Metallized Polyethylene Terephthalate) which is the material used in space blankets and reflects “97% of radiated heat” ( This means that the air within the cavity will be kept cooler for longer resulting in lower gas use.

Pressure Vessel & Gas Laws Through Ideal Gas Laws, I have calculated that it would be feasible to use compressed gas to cool the air. However, to chill the air with just compressed gas to the temperatures needed, the pressure would be too high for the canister. So, the solution is to add a liquid coolant which will react with the air when ejected from the canister. Using 2 x 500ml Canister’s and a low volumetric flow rate, the jacket can be cool for a full 27 minutes, spraying the gas and coolant in 45 second intervals. The inlet pipe injects the compressed air coolant mix into the jacket, as the mixture is injected the outlet valve will release a certain amount to keep the pressure constant. Enclosed within the inlet pipe is a temperature sensor to ensure that the temperate is at the correct level to cool the body effectively.


Samuel Thomas Moseley (BSc Hons) Product Design Bournemouth University

FORD Transit Climate Outlet Adapter

Brief To design an adapter that will be used in conjunction with the development of the Ford Transit HVAC ( Heating Ventilation and Air Conditioning system). It will be used to attach measuring equipment for the analysis of airflow distribution. The adapter must be designed to be durable and robust to within stand the long time periods of testing.

Solution The adapter was created using CATIA V5 and Teamcenter. The renderings to the right hand side of the page were produced using Keyshot 2.1. Ultimately the adapter will be made using SLS rapid prototyping as it is an inexpensive way to produce a bespoke product. This allowed me to use an alternative design method using undercuts and varying wall thicknesses. The bottom interfacing plate simulates the instrument panel of the Transit. The intention for this is to create the most realistic testing conditions possible and this would replicate the integration between the HVAC and the IP.

ADAPTER - Features The W3mm x H15mm ribs on the base are designed to reduce the chance of torsion misshaping of the adapter. Furthermore, the reinforcement plate (top third of the adapter) is to aid users when attaching measurement tubes. The plate doesn’t allow the tubes to pass the defined point. The text “V362 Front HVAC - Panel VP Build” This is so that the adapter is easily recognisable as there will be many adapters throughout the course of development.


Samuel Thomas Moseley (BSc Hons) Product Design Bournemouth University




Samuel Thomas Moseley (BSc Hons) Product Design Bournemouth University

FORD Transit Climate Assembly Fixture

Placement Brief In my year spent in working Cologne, Germany, as part of the climate team for the Ford Transit Van. This was the first project I began with.









The images are of a fixture designed to aid the assembly of the long wheeled based Ford Transit Van HVAC System (Heating, Ventilation and Air Conditioning). The fixture was originally used in Charleville-Mezieres, France for pre-production prototypes and eventually moved to Turkey. The CAD model was designed using CATIA V5 and machined using a CNC machining centre. It is made from aluminum and located underneath are polyamide risers. Using the risers allows for clearance of the housing to the workbench and weight reduction for ease of transportation.

Image Description Image 2 : Shows a Location Cylinder which has a 90째 dial insert and allows the pin to be centered in the predetermined assembly position ready for the Kinematic and Motors. Image 4 : Shows how the Location Cylinder has been used. The red grooves are taken from the door assembly of the HVAC and are machined into the fixture block. When the dial runs parallel with the red groove the door pin is in the correct position. Image 7 : Shows how the left hand side housing fits into the assembly fixture with doors assembled in the correct position. Image 8 : Completed Assembly


Samuel Thomas Moseley (BSc Hons) Product Design Bournemouth University

Samuel Thomas Moseley - Portfolio  

A short collection of my work.