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ZM Industrial Design Portfolio 18’

0.1 Hello!

My name is Zak. I am a industrial design student at loughborough university, looking for a placement opportunity starting september 2018.

Experience: Camp Counselor | Summer 2017 Camp Walden New York Intern | 2014-2017 SRLV Accountants Camp Leader | 2013-2017 Highland Games Acvitivy Weeks Intern | Summer 2015 The 10 Group

Education: BA Industrial Design | 2016-2020 Loughborough University A Level And GCSE Qualifications | 2009-2015 University College School

0.2 What’s Inside. Pop.




“Design a homeware product for

“Design a promotional item for a

“Re-design the fold-up chair by

“Design and create a mobile

student living using polypropylene

chosen brand along with an

utilising high quality materials

speaker through the process of

as the predominant material,

injection mould tool which allows

and appropriate ergonomic data

CAD surface modelling in order


for the production of the item

to create a more appealing



product which saves space in the

understanding of 3D modelling


of complex forms.”




mechanism in order to allow for


compact storage.”






1.0 Pop. “A multi-purpose, stackable, dry-wipe flatpack shelving unit, designed for students.�

1.1 Persona. This is Andrew.




Aged 21 Lives in halls accomadation Studies French and Spanish Student at Loughborough University

Gain more storage space Reduce clutter in bedroom Organise textbooks for accessability Write notes efficiently and effectivley


Pain Points.

“My room in halls is pretty small and there isn’t enough storage space so I always struggle to find the right books and keep all my things organised.”


Lack of general storage space Student budget restricts money Existing alternatives don’t fit in bedroom Room is usually messy and hard to organise Nowhere accessable to display notes or books

1.2 Ideation & Prototyping. After making some quick concept sketches of my design based on the key issues that Andrew rasied, I went straight into crafting a functional full scale model out of foam board. This allowed me to get a realistic feel of the sizing, functionality, and aesthetic, as well as test how people behaved with it.

sketching ideas

making the card model

testing prototype functionality

visualising product scenario

1.3 Scenario.


The student enters his his desk is overflowing he has nowhere to


3M self adhesive are applied to Pop frame.

He finds his opens it up well needed

room and notices that with clutter, and as such store his new books.

strips the


The Pop frame is the wall securely can be placed


pressed into and books on the shelves.


Each pair of supports are popped followed by the corresponding shelf which slot securely into the support

Pop shelving unit and to full size to gain some extra storage space.


If the student he can pop write on the

wants to write notes, the shelves in and dry-wipe coating.

out first, cutouts extrudes.


Pop can be and stored in without any

de-mounted it’s flatpack form hassle or damage.

1.4 Product Lineup. Pop has a coupling hinge system at both ends of its frame and a repeated system of live hinge cutouts down its face, which allow it to fulfill various purposes. - Fold both ends together and flatten along all hinges for flatpacking. - Bend the frame at a 45° angle and open up shelves to use as a desk tidy. - Flatten and wall mount to utilise the dry-wipe coating as a whiteboard. - Pop out the shelves and wall mount for convinient shelving storage.

Flatpack. Flatpack.

Desk Tidy. Desk Tidy.

White board Whitebo ard..

Shelving Unit. Shelving Unit.

2.0 Leveroo. “An injection mould tool and injection moulded promotional bike tyre lever widget, designed for deliveroo.�

2.1 Prototyping. This was a group project where

Top Mould Block

individual designs had been drawn up previous to the project start, so while the widget design was not mine it was the job of me and my team to make the widget design

Line-Up Pins

viable for injection moulding and then manufacture the mould tool out of steel blocks. We prototyped the design to check that it would work. To do this, we 3D

3D printed rapid prototype widget

printed the widget and CNC milled a foam model of the mould tool.

Inserts and Donor Part

Bottom Mould Block CNC milling

rapid prototype foam mould tool

2.2 Manufacture. Firstly, the mould blocks were created using the CNC milling machine, using our desgn from HSM works. Then the donor part was created using the water jet cutter which followed a 2D software to machine an 8mm sheet of mild steel. I then cut, turned, and faced all the

CNC milling

water jet cutting

manual milling

line up pins using the centre lathe. We manufactured each insert using




machine, and drilled all the pin holes using the pillar drill. Lastly, I used the surface grinder to flatten every insert down to correct tolerances so that the entire mould tool would sit flush together and be ready to

pillar drilling

surface grinding

finished mould tool


create the perfect

2.3 Mass Production. The final part of the project was to propose a plan for mass manufacture of the widget over a three month timeframe.

To make the design

64,663 Injections per week


target, we would use

258,652 Widgets per week

a quadruple widget mould cavity set in

3,103,832 Widgets in three months

series to produce four widgets per injection.


1. Fill Time: 0.96s


2. Hold Time: 2.87s

5 4

9.65s Per Cycle


160 Hours 27.7g Plastic per injection

viable for the required mass

3 Months


3. Cooling Time: 3.1s 4. Opening Time: 0.9s 5. Ejection Time: 0.54s 6. Mould Close: 1.28s

2.4 Promotion al Usage. 1

The Deliveroo rider picks up an order and is on his way to the delivery.


The rider notices a problem with his bike and checks his tyre for a puncture.


The rider uses the widget to remove the tyre in order to fix the puncture.


The rider gets back on their bike and cycles to their order with a fixed tyre.

3.0 Fold. “A luxurious, ergonomic, dual-purpose, folding chair/table, designed for households.�

3.1 Ideation.

To start the project, I went through a process of quickly thinking of a foldable chair concept, modelling it in foam, and then adapting it to see what I could make of it if developed.

3.2 Refine & Prototype. I decided to visually prioritise what I wanted out of my design , using the feedback I gained from my foam modelling in order to refined my idea into one solid and functional concept.

I made a full scale prototype of my design in 2D, using a simplified version of the folding arm leg mechanism to test out ergonomics and the functionality of the idea. I then finalised plan drawings for the design to be dual purpose, as hinged folding mechanisms allow it to function as both a table and a chair. The main body is able to fold flat to act as a tabletop surface, while the joining arm rest / chair leg systems are able to fold down into itself. I also designed a pair of leather cushions which provide lumbar support and fit together in tessellation to allow the chair to fold flat.

3.3 Manufacture. I personally planned out and untertook the entire manufacturing process, first using a CNC router to cut out the main plywood framework pieces, which I later applied walnut veneer to. I then cut down large walnut planks to specific sizes to

CNC router

walnut veneer

sandwhich glueing

make the folding the armrest and leg system. After securely glueing together each coupling component with dowel and sandwhich joints, I sanded the surfaces of all materials smooth and applied a wax coating to each piece. Next, I custom made leather covered foam cushions using shapes that promote lumbar

plank sizing

wax coating

upholstery fabrication

support which I designed using ergonomic data from the british standards institute publishings. Lastly, I assembled all pieces together with nuts and bolts, joined a metal hook to the front to hold the chair flat when closed, and attatched a small pivoting latch mechanism on each side of the armrests to allow them to be locked or unlocked when upright.



arm lock

assembled & finished product

lumbar supportive armchair.

[folded] sharable robust coffee table.


3.4 In Use.

4.0 SoundBomb. “A branded, stylised, multi-directional mobile speaker, designed through surface modelling.�

4.1 Inspiration.

Firstly, I did some general research into a variety of interesting and rugged forms that maintained stylised aesthetics. I then narrowed it down to six products, of which I analysed the key design features that I felt captured useful characteristics which I could potetially utilise in my design. These distinctive features were the stylised symmetrical surface cut outs, the hexagonal surface form, embossed branding, a double helix exoskeleton, rounded concave speakers, and the red on black ‘explosive’ contrasting aesthetic.

4.2 Ideation. I then started sketching simple 2D forms which I drew from my inspiration in order to asses what kind of form I wanted to create. I drew a lot of symmetrical forms, as I had an idea in my head that I wanted my speaker design to be able to stand itself at any orientation.

I then began to refine my idea, and so I set on a hexagonal base and worked up from there, using symmetrical patterns and an exterior double helix to give the design a distinctive character.

4.3 CAD Modelling. The early models I designed featured the same steel double helix exo-skeleton and hexagonal body shape, however in the final model I embossed the Soundbomb logo and emblem onto the body, giving clear brand recognition, and added volume, bluetooth, and power buttons onto the base to allow for clear and intuative control of the speakers functions. I also finished the final model in only gloss and matte blacks, while early models surfaces varied in prime metallic colours.

I evaluated my final design using the zebra stripes feature with Solidworks surfaces, which allowed me to check the curvature continuity across the entire body of the design, ensuring a seamless surface.

4.4 Mock Up.

explosive multi-directional sound | wireless connectivity gloss or matte finish | touch sensitive controls changable orientation | rubberized feet

what I get up to when I’m not designing.

Thank You! Feel free to contact me.

Zak Marks | Industrial Design Portfolio | Loughborough University  

Hi, my name is Zak - I am a second year Industrial Design student at Loughborough University and this is my 2018 Portfolio | My CV is availa...

Zak Marks | Industrial Design Portfolio | Loughborough University  

Hi, my name is Zak - I am a second year Industrial Design student at Loughborough University and this is my 2018 Portfolio | My CV is availa...