NEST Form Development

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Development Portfolio

NEST

Voronoi Structure

Oliver Leigh

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FormVoronoi Structure

Follwing the ideation stage of this project, I will now develop my choosen idea. I will develop the form of the prodcut to best suit the needs of the user, whilst also developing technical factors that will allow the product to become feasible.

The structure of this report is as follows:

Form development

The inital sections of this report focus on the form development. I will gain user feedback in the form of police contact to ensure that I develop the product succesfully.

Technical

The technical sections containing materials test, Design for manufacture, Design for Assembly and Technical Drawings will follow.

Introduction

The intended outcome of this development sprocess is to produce a structure that will create a new way in which we use public space. The struture will use an elastic material to create seating pockets, whilst also including bluetooth technology allowing the users to wireless stream their own music whilst using the product.

Attractive Sturcture

Seating Pockets

Bluetooth Wireless Music Streaming (Existing technology)

N.B. The bluetooth technology will be addressed if time allows, the reason for this is, Bluetooth wireless streaming is an exisiting technology. Efforts will e focussed on the seating and structural elements of the product before developing the music technology.

Product Concept

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FormUser Requirements

Opp.

What is therefore required from my product

Requirement

What do we mean by this

ASB is a waste of Police time and as a

result, Tax Payers money

Must lower the amount of Police time

needed to counter ASB

Must decrease the need for Police

prescenece

Must be a free standing Product that

requires no Police attention to run

Secondary Opp.


Requirement


How might we deter Youths from

misusing Public Space

Must provide an alternative meeting

point for youths, that can be monitored

Must Provide a safe place for youts to

congregate

Must cater to youths needs and wants

whilst allowing public to feel safe

Primary Opp.




How might we bridge the cultural

difference throughout UK City Centres

Must provide comfort for other City

Centre Users

Must highlight the potential danger areas

within the City Centre

Must Highlight the Actions of Groups of

Youths throughout the City Centre

Lit Reveiw

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Social Pleasure

Social

The social aspect of my design is crucial to its success. To achieve the social desirability relationship with the user, my product must facilitate a positive social experience. The product will achieve this through its form and its location. The Product will be designed using current design influences, feedback from the end users (Aged 13-22).

The product will be located within existing public space; the product will aim to create a busy social environment that invokes a positive social experience through interaction with the wireless music system and the overall shape and form of the product.

The materials used for the main structure and seating pockets will be considered to encourage further users to engage with the product and give the socially desired impression. The colour of the main structure will also be considered to positively affect the social desirability of the structure; appropriate colour choices will encourage use.

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Physical Pleasure

Physical

The physio-pleasure aspect of my design will be achieved through the interaction between the user and the main structure. The Structure will include seating pockets that allow the user to lie and ‘relax into’ an elastic material. The elastic material will provide a comfortable seating position; the physical pleasure of sitting within the pocket and the comfortable fit will encourage physical desirability within the product.

The main structure of the product will be manufactured and assembled to fit within a +0.1mm tolerance. The assembled product will look elegant through form development whilst also feel as if its heavy and tough when the user interacts and feels the structure. This quality of finish will be achieved using appropriate materials and finishing processes, subsequently this will encourage further physical desirability within the product.

The finish of the product is crucial to the success of the product. Existing products in the public space market are susceptible to deterioration and inevitably neglected. To ensure my product is successful in its intended market, material choices and finishes must be considered.

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PDSProduct Design Specification

Following the Market Research and Ideation stages of this project, it has been decided that there is a need for a product installation that engages and entertains 11-17year old in and around UK City Centres. The product should be a free standing assembly that allows the end users to relax and ‘hang-out’ within public space areas. The product will include 2 different Modular sections that will allow the council/local organisations to purchase and create bespoke public space installations in variation of form. The product will also include wireless music playing capabilities allowing the users to play their-own music at a pre-determined level.

Introduction

This specification covers the general operational characteristics of the product and provides an overview of the requirements for the finished article. This is response to the criteria set throughout the research and ideation stages of the Project. The specification will outline specific manufacturing aesthetic details for the finished product.

Scope

References

Standards and specification to adhere to:

BSI EN 1176-1: 2008; Playground Equipment and Surfacing- General safety requirements and test method.

ISO 9000 – Standards relating to Quality Management

BS 5760-3:1982- (Reliability of systems, equipment and components)

BSI EN1176-2: 2008 (Additional specific safety requirements and test methods for swings)

PDS- Product design specification

Db- Decibels

N- Newtons (Measure of Force)

Definitions

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PDSPerformance Requirements

1.0 Function

1.1 Product must provide an alternative space for youth/users within public space areas. Modular design will allow councils to purchase pieces individually to create bespoke public space installations.

1.2 The space created by the assembled products must encourage youths to behave in appropriate way when using. Through attractive

1.3 The space created must allow users to be seen by general public and policing forces when in use. Modular sections will allow councils/authorities to determine shape and form of space to ensure visibility of users at all times. Smaller sections should not exceed 1500mm in height to allow for external visibility.(Average height of an adult, therefore allowing users to be seen when using/within the space)

1.4 Product must also provide music capabilities and allow for 15 users to stream their own music wirelessly using lamppost attachment.

1.5 Lamppost Attachment must also monitor sound levels of immediate surrounding space and alert authorities when sound levels are breached. Product must alert authorities when decibels exceed ***** (Acceptable noise levels in public space)

1.6 Each modular piece of Product must sufficiently support the combined weight of more than 4 end users. Product must be over engineered to withstand a combined weight of 6 adults. Test using Finite Element Analysis. BSI EN 1176-1: 2008; Playground Equipment and Surfacing- General safety requirements and test method.

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2.1 Product must be an interesting shape and form to draw and attract users attention. Use of Voronoi Inspired Organic Parametric Pattern.

2.2 Product must appear to be aimed at 13-25 year olds, modern materials and finishes used.

2.0 Appearance

3.1 Product must be able to operate outdoors constantly for 2-3 years, without failure or deterioration.

3.2 Durable Material used for seating pockets, all weather resistant.

3.3 Materials used for seating pocket material attachment will be moulded from high density, shatter resistant polymer.

3.4 All mechanical fixings through the product must be stainless steel.

3.5 Material used for outer shell of Lamppost Attachment will be moulded high density, shatter resistant polymer.

3.6 Innner workings of lamppost attachment will be fixed and attached to lamppost using stainless steel skeleton frame.

3.0 Reliabillity

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Product must be fit for use in a variety of different locations,

4.1 Product will mainly be used in European environments, Temperature ranges from 0-28 degrees C-European, 12-44 Degrees C- Far East.

4.2 Product will be exposed to large quantities of shock loading; each modular section must be able to withstand combined weight of 6 users. Users assumed to be adults (extreme scenario) 6 x 70KG = 420kg of Shock Loading. Test using FEA

4.3 The product may experience humid temperatures.

4.4 Corrosion resistance may be considered through the use of specialised materials or surface protection methods.

4.5 The product may be exposed to large amounts of UV light; the product must be able to withstand damage accordingly.

4.6 The product will be exposed to the elements all year round and therefore will need to be water resistant. Product must be tested up to an IP rating of IP X6- Protected against temporary flooding of water. Ingress Protection Rating

4.0 Environment

5.0 Production Cost

5.1 Each modular section should have an end-user cost of 750 pounds within Britain. (Contact Dynamo and competitors to find similar prices)

5.2 Cost of Manufacture should not exceed 350 pounds.

5.3 The cost of packaging and shipping should not exceed 20% of the manufacturing cost.

5.4 The cost of Installing the product should not exceed 250-500 pounds. (Research similar installation costs of installation)

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PDS

(Product must provide comfortable ‘hang out’ space for youths)

6.1 Product form must allow for end users to populate structure in casual manor. Test will be carried out to gain user feedback on comfort and social capabilities.

6.2 Materials used for ‘seating pockets’ must deform under weight of end user and allow for comfortable seating when using product. Materials used must posses’ elastic properties. Use of CES EduPack to determine which materials to test. Test materials on scale rig to determine most appropriate material for ‘seating pockets’

Material’s to test: Thick Rubber Band Bunji cord Elasticised Cordue/Tape Silicon Pod Lycra Cover Mesh Rubber Sheet

6.3 Ease of Use, the product must enable the end user to easily enter and exit the seating pockets. Angles of seating pockets will be considered to achieve thid. Users testing, gain feedback on ease of enter and exit, adapt design accordingly.

6.0 Ergonomics

Performance Requirements

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7.1 All manufacturing process and manufacturers must comply with ISO 9000.

7.2 Product must adhere to all safety and testing regulations in relation to available public space standards. Product will be tested against

BSI EN 1176-1: 2008, (General safety requirements and test methods)



7.3 Quality should be as such that the product does not generally fail for 2-3 years and only 1 in 100 should fail within the first year.

7.0 Quality

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PDS

(Product must provide comfortable ‘hang out’ space for youths)

6.1 Product form must allow for end users to populate structure in casual manor. Test will be carried out to gain user feedback on comfort and social capabilities.

6.2 Materials used for ‘seating pockets’ must deform under weight of end user and allow for comfortable seating when using product. Materials used must posses’ elastic properties. Use of CES EduPack to determine which materials to test. Test materials on scale rig to determine most appropriate material for ‘seating pockets’

Material’s to test: Thick Rubber Band Bunji cord Elasticised Cordue/Tape Silicon Pod Lycra Cover Mesh Rubber Sheet

6.3 Ease of Use, the product must enable the end user to easily enter and exit the seating pockets. Angles of seating pockets will be considered to achieve thid. Users testing, gain feedback on ease of enter and exit, adapt design accordingly.

6.0 Ergonomics

Performance Requirements

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7.1 All manufacturing process and manufacturers must comply with ISO 9000.

7.2 Product must adhere to all safety and testing regulations in relation to available public space standards. Product will be tested against

BSI EN 1176-1: 2008, (General safety requirements and test methods)



7.3 Quality should be as such that the product does not generally fail for 2-3 years and only 1 in 100 should fail within the first year.

7.0 Quality

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PDSManufacturing Requirements

8.1 The final prototype must be suitable for manufacture using existing manufacturing techniques along with university available equipment and processes:

Makerbot 3d Rapid Prototype 3D Printer Z corp 2510 Laser Cutter Modelling Clay Woodwork workshops (includes band saws, sanders, drills etc.) Metal workshop (CNC machines, welders, etc)

8.2 The modular structure voronoi surfaces of the product must be achievable using available manufacturing techniques and services. Modular sections to be moulded in solid plastic sections, with fixing holes in place. (Slides Manufacture GRP)

8.3 The Support structure will be made of welded steel tube, providing critical support for the Voronoi surfacing of each modular piece to attach to. (BS EN 1176-1:2008 4.1.4 – Metals)

8.4 The Seating pockets will be purchased as sheet material and cut to size using a laser cutter.

8.5 The seating material attachment components will be manufactured out of re-enforced plastic.

8.6 The lamppost attachment will be manufactured in a 2 part plastic moulded outer shell, with a stainless steel

8.0 Process

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9.1 Materials shall be selected and protected such that the structural integrity of the equipment manufactured from them is not affected before the next maintenance inspection. BS EN 1176-7 (Recommendations for maintenance inspections)

9.2 Materials used within the product should be manufactured in a workmanlike manner.

9.3 The selection of materials and their use within the product must be in accordance to European Standards.

9.4 Metal Parts should be protected against atmospheric conditions and cathodic corrosion. (BS EN 1176-1:2008 4.1.4 – Metals)

9.5 Materials used within the main Voronoi Surfacing must comply with BS EN 1176-1: 2008 (General Safety and Testing Methods)

9.6 Materials used within the ‘seating pockets’ should have elastic properties and deform under force. The material must successfully incur the force of 2/3 users (Maximum) whilst sill returning to its original form. (Test using small and full size testing rigs) Must comply with BS EN 1176-1: 2008 (General Safety and Testing Methods)-Materials.

9.0 Materials

10.1 The products (Modular Sections) will be assembled and installed on site at destination of use.

10.2 Simple fixings used to allow ease of assembly.

10.3 Product must allow for disassembly when necessary through reversing the assembly process.

10.4 Each Modular section should be fully assembled within a 30-minute period. (Time allowed for weather conditions and conflicting organisations)

10.0 Assembly

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Storage of Excess Components and Product

11.1 Once the modular sections have been manufactured, the sections will be stored in a central location ready for distribution to end user site locations.

11.2 Any components that have been manufactured and stored for over 6 months must be fully tested before sale and use.

Packaging and Shipment

11.3 The Steel frame structure will be manufactured and then wrapped in protective pipe lagging before transportation.

11.4 The Voronoi Moulded Surfaces will be manufactured and finished accordingly before being covered in protective wrapping prior to transportation.

11.5 The Voronoi Surface pieces will be assembled and fitted with the seating pocket material prior to on site assembly.

11.0 Packaging

12.1 The Product has been developed for mass manufacture.

12.2 Each Section will be manufactured in quantities of 100-500 in the first year. Increasing to 1000 within 5 years.

12.0 Quantity

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PDSOperation Requirements

13.1 Delivery of the product will include all the sections specified by the purchaser, i.e council/local authority.

13.2 Delivery of product will include a full equipment and parts list for assembly and installation.

13.3 Installation instructions for the product will include an instruction manual outlining the correct erection, assembly and placing of the product methods in relation to the product:

This information must include: Minimum space requirements and safety clearances. Equipments and parts identification. Erection Sequence. Matching aids where necessary, e.g. informative signs on parts, accompanied by appropriate instructions. Drawings, diagrams clearly specifying the principal dimensions of the equipment and the relevant space, heights and areas required for installation. BSI EN 1176-1: 2008, (General safety requirements and test methods)

13.0 Installation

14.1 Assembled structure will allow the user to ‘hang out’ in and around the Voronoi Surface Structure

14.2 Assembled Structure must allow user to easily enter and exit seating pockets.

14.0 Use

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PDSOperation Requirements

15.1 Product will be provided with the necessary instructions for maintenance. (Inspection standards needed/referenced)

The instructions must outline: The necessary servicing points (Tightening of Bolts) Identification of spare parts Keeping Drainage holes clear That GRP should be replaced before glass fibres becomes exposed through wear or damage.

15.2 The product must be easily cleanable using widely used cleaning methods, i.e. jet washing, hand washing etc.

15.3 All mechanisms must be accessible for repair and replacement with ease. All enclosed mechanisms and fixings should be accessible within 15 minutes without the use of specialist tools or equipment.

15.0 Maintenance

16.1 Product must adhere with BS EN 1176-1:2008 Safety Regulations in relation to playground and play area installations. Safety issues such as:

Entrapment of head and neck Entrapment of clothing/hair Entrapment of fingers Falling heights Entrapment of the whole body

16.0 Safety

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PDSAcceptance Standards

17.1 Before product’s first use, the structure will be inspected thoroughly on an operational level and on a visual level.

17.2 Annual Main Inspections will occur to comply with BS EN 1176-1: 2008- Playground equipment and surfacing- General Safety and Testing Methods.

17.3 Typical checks include effects of weather, evidence of rotting or corrosion and any change in level of safety of the structure. As a result repairs will be made and parts changed where necessary.

17.0 Inspection

18.1 Functionality and Safety Testing must be carried out on 5% of all units produced.

18.2 Material for seating pockets will be tested for functional capabilities and safety compliance with BSI EN1176-2008; Playground Equipment and Surfacing- General safety requirements and test method – Fibre ropes and Netting (4.2.12.5)

18.3 All seating pocket material attachment components shall be tested and comply with BSI EN1176-2008; Playground Equipment and Surfacing- General safety requirements and test method- Connections (4.2.1.0) . Finite Element Analysis will be carried out to determine shearing/breaking point of component.

18.4 Material used for Voronoi Surfacing must be selected and tested such that the structural integrity of the equipment manufactured is able to withstand the combined (maximum) weight of end users. Tests will be carried out using Finite Element Analysis and then tested on a full size scale mock-up of modular sections.

18.5 All testing methods and results will be published and available for review in the public domain.

18.0 Testing

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PDS

19.1 BSI EN 1176-1: 2008; Playground Equipment and Surfacing- General safety requirements and test method.

19.2 BSI EN1176-2: 2008 (Additional specific safety requirements and test methods for swings)

19.3 BS 5760-3:1982- (Reliability of systems, equipment and components)

19.4 ISO 9000 – Standards relating to Quality Management

19.0 Standards

20.1 Patents exist in public domain, encompassing public space installations and interaction display in private space of Public space (CN103198776 A).

20.2 No patents found that directly link to Modular Voronoi Public Space Installation with Wireless Music Capabilities as of yet.

20.0 Patants

Acceptance Standards

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PDSDisposal

21.1 Product will be designed to be easily unassembled without the need for specialist equipment and tools.

21.2 Product will be provided with the relevant information indicating which parts and components can and should be recycled.

21.0 Policy

22.1 Care must be taken when disposing of main structure support frame. Support structure may have been damaged or deteriorated over products life.

22.2 Care must also be taken when disassembling the entire installation, heavy and obscure shaped parts could cause potential dropping hazards.

22.0 Hazards

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PersonaTranslation

To allow myself to undrstand my users needs and wants, I have developed a persona of a typical user. This will allow me to ensure that I design for a specific users needs. The graphic clearly shows the attributes and characteristics of my ‘user’.

Ben

16Lives at home with both Parents

Student

Weekend Job

Social

John

75Lives with wife

Cab Driver

Retired

Social

Regular Bridge Club

Football at the Local Pub

Meals out with the Family

Going to houseparties

Playing at Friends Houses

Skatepark with mates

Issue

Friends Houses becoming too closely

monitored for me and my friends,

but were not old enough to go

clubbing in town yet.

Going to houseparties

Issue

Enjoy going out with my

family for regular meals, but I

am getting older and dont feel

safe walking home through

some of the dark Pathways.

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Form and the users

Throughout this section I wil design, develop and redesign my products form to best suit my intended users needs and requirements. During the course of the development process I will regularly meet and discuss my development with a variety of users and potential clients, this will ensure that I am able to successfully meet my users needs and requirements.

Introduction

When designing the form of my product, there are a number of requirements and governing standards that must be considered and adhered to from the offset and throughout. The bullet points below highlight the main requirements that my product form will need to successfully fulfil, these points can also be found within the Product Design Specification (PDS):

Product must provide an alternative space for users within public space areas.

Product must be an interesting shape and form to draw and attract users attention.

Product must appear to be aimed at 13 to 25 year olds, modern materials and finishes used.

The space created must allow users to be seen by general public and policing forces when in use.

Key areas to Consider

The prodcut will be situated in pubic space, therfore the users could be anyone. The product will be designed geometrically to adhere to existing ergonomic data relating to the averge man/women. Anothe rone of the prodcuts main functions is to reduce anti ocial behaviour within city centres in the UK, throughout the project i will gain insights and opinions from existing memebers of the Sussex Police Force to ensure my design achieves its function.

Who are the users

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FormUnderstanding The Users

To begin the form development process a better understanding of what my targeted user groups design likes and dislikes was required. To aquire frist hand feedback on what 13-25 year olds find interesting, attractive and enjoyable

Design Inspiration

The test consisted of a number of pattern inspired design images, including modern public space structures to coneptual architechture. 20 images were shown to a group of 13-22 year olds, the group test was unanimous and the majority fvoured the Voronoi inpired designs.

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FormVoronoi Tesselation

In mathematics, a Voronoi diagram is a way of dividing space into a number of regions. A set of points (called seeds, sites, or generators) is specified beforehand and for each seed there will be a corresponding region consisting of all points closer to that seed than to any other. The regions are called Voronoi cells. It is dual to the Delaunay triangulation.

Explained

Voronoi diagrams, tesselations, polygons have previously been used within a variety of real world applications, the mathematically driven pattern can be found in mathematical research, architechtural design and even the medical industry. The list below further outlines the use of Vornoi within todays Society.

Applications

Medical Industry

Voronoi is named after Georgy Voronoy, and is also called a Voronoi tessellation, a Voronoi decomposition, a Voronoi partition, or a Dirichlet tessellation.

Mining Industry

Architectural Design

Computer Graphics

Robot Navigation

Ecology

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To better understand the Voronoi pattern in a 3 Dimensional form, a clay model was produced using a laser cut form mould. By layering the clay evenly inside the mould, the vornoi pattern could be cut out before the clay dries.

Prototype 1

In order to create the voronoi pattern upon an inverted surface, a mould was required. The moulding box was laser cut out of 6mm MDF, with an appropriate hle to accomodate the acrylic hemisphere. This mould allows for the clay to be rolled evenly thick and then laid over the base of the mould.

The pictures below show the moulding box and how it assembles.

Building the Mould

To create even thickness within the clay, two 6mm pieces of MDF and a rolling tube allow for the clay to be rolled and cut into strips. These stripes are then placed within the mould and manipulated together using water as a bonding agent.

Rolling the clay flat

6mm MDF

6mm Rolled Clay

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The section view diagram above shows how the clay was laid within the MDF moulding box. The seperate strips of clay were then manipulated together using water.

Laying the Clay

Using existing voronoi images as inspriation, the Voronoi pattern was cut out of the freshly laid clay. The clay was cut using a blake and various clay working tools.

Cutting the Pattern

6mm Rolled Clay

6mm Moulding Box

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FormPrototype 1

The pictures below show the clay model that was removed form the mold. The form ws then assessed and evaluated before development.

End Result

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FormForm Development

Prototype 1

Prototype 2

The form of Prototype 1 was then evaluated and deemed to be to steep in wall angle. The design was then changed and Prototype 2 was created. The use of shallower wall angles will allow the user to sit in a more ergonomic positon, increasing the comfort.

End Result

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FormVoronoi CAD Construction

T-splines is an Autodesk plug-in for Rhinoceros, it uses mathematical algorythms to ease the process of achieving complex surface modells in CAD. Through the use of T-splines within Rhino, I was able to create NURBS and then manipulate/bridge specific faces to create my desitred geometry.

The images below show exising Voronio themed constrctuons using T-splines.

T splines

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Within T-spline, there is a feature which allows to deformation and blending of faces. Through using this tool I was able to place T-spline’s Primitive Geometry (Quadball, Torus, Box) and select the apropriate faces to blend. The images bleow show the initial gemoetries I constructed when originally trying to understand T-splines and its functions.

Face Bridging

FormVoronoi CAD Construction

Once I was able to understand and manipulate T-splines primitives into organic shapes using the ‘Face Bridging’ tool, I then turned to Solidworks to create a surface model of the shape I intended to create. By creating a surface model in Solidworks that resembled the genrla shape of the product, I was able to place T-plines primitives at each surface intersection. The pictures to the left shows this process.

Using Solidworks Surfaces

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Following the creation and development of Prototype 1, the design was developed. Prototype 2 uses a much less aggressive wall anlge. This allows the the seating pockets to be formed at a more ergonomic angle.

To create this model, first a surface model was created in Solidworks

Prototype 2

T-splines primitives were then place on each surface intersections and the face bridging tool was applpied.

85

00

mm

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The images below show the CAD process from a 3 Dimenisal perspective.

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Once the CAD was complete, the model was sent to print. The model was printed using the Universty poweder printer. The Model was printed and then sealed using resin. The follwing images depict the 3d Powered Print process.

Printing the Prototype

The form was then evaluated and developed. The form was deemed to be too steep in wall angle again. The geometry created would result in the use of the product to pose a danger to the user. Potential fall heights would conflict with existing standards and the product PDS.

Evailuation

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The image below shows the prodcut in situation. The product will be sunk into the ground, creating a negative bowl geometry. The cyclist was added for scale reference.

CAD in Situ

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To overcome the wall steepness, the product has been developed and the overal size of the product has been increased. The form development now includes flat levels to enable the user to access the space with ease.

Prototype 3

The CAD model of the prototype was constructed in the same way as the previous. An existing voronoi pattern was used to map out the Solidworks surface model before the model was placed into Rhino.10500mm

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The prototype was created using the face bridge tool in T-splines. The image to the left shows the prototype in situation. The development in form will now allow the user to access the space, less agressive angles will allow the user to climb into the product.

Once the CAD model had been created, the model was sent to print. However, due to the complex geometry of the shape and the nature of the scale, the modelwas unable to support itself and descintegrated upon removal form the printer.

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FormContact with Police

CAD

The image below shows Prototype3 in situation. Again the product will be sunk into the ground and allow the user to ‘climb’ into the space. The sunken geometry will create an interesting public area that can be enjoyed by all.

Evaluation

Prototype 3’s form will succesfully achieve the products function. The space created by the product will be extremely unusual and spark interest within the community. The product will engage the youth of the community and provide them with a well lit space to use day and night.

However, the form of Prototype 3 may also pose potential hazards and threats. The way in which the user ‘climbs’ in and out of the space may cause the user to fall, or damge themselves.

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Form

At this stage in the design process, user feedback was needed. To make sure the product is successful in its function, I was able to organise an interveiw with a member of the Sussex Police. I met with Katherine Davies, a Police specialist in Public Space Design, to discuss my desgins at length.

Interveiw Outcomes: The way in which the voronoi pattern is used to create the shape, was praised. The overall idea of the project was described by Katherine as exciting and new.However, the overall form of the product was critiscied, Katherine was concerned with the visibility of the users when the will be using the product and the space it creates.

Contact with Police

The image above shows the issue. When the product is sunk into the ground the visisbllity sight lines are limited. The product needs to create a well lit space that enables the community to clearly see ‘what is going on’ inside the space created. The form must be developed.

Evaluation

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Human FactorsAnthropometric Data

Seating Pocket Siizes

Bfore the form was redeveloped and produced using CAD software, I took this opportunity to consider the ergonomic factors face with the seating pockets. The size of the pockets will be determined by the overall form of the product, to successfully create a comfortable seating pocket for each user I will look at relevant existing anthropometric data and develop the form accordingly.

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Human FactorsApplied Data

Seating Pocket Siizes

After evaluating the data collected in regards to human size and sitting position, the data was applied to the design. The nature of the design means the that each seating pocket will be different in size and shape. To enable the user to comfortably sit within each seating pocket, the geometry of follwing prototype will include this data. The images below show the minimum and maximum size the seating pocket should be to succesfully create a comfortable seating pocket.

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Prototype 4, was created to suit the recent developments in the overall form and function of the product. The prototype has been designed to consider the sight lines created by the product, whilst also including the anthropometric data collected and applied in the previous page. The images below show the form and function of Prototype 4.

Prototype 4

Possible Modular Assemblys

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mm

The shape was created to become a large modular piece. The form will allow the client, to create bespoke modular assemblies each with their own unique space

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The size and form of this protoype is organic and complex. At this stage in the design process I needed to consider how this complex geomoetry might be manufactured and assembled.

Manufacture

The diagram above expalins the possible splitting of the overall shape of the product. By splitting the prodcut into 3 smaller sections the form can be molded and assembled. Whilst designing the form I must also consider the way in which

the seating pocket could be attached. The material fixing points shold be hidden from the user to remove any potential hazards and risks.

Attaching the Seating Pocket Material

The diagrom to the left shows how the seating pocket material could be attached between two parts of the product. To achieve this attachment

Top Molded Piced

Seating Pocket Material

Lower Molded Piece

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Sight Lines

Prototype 4 was created to adhere with the new guiedlines set ut by the Sussex Police. The product must enable the community and the Police to see what is going on within the product itself.

The image below shows the previous design Prototype 3 and the sightlines that are created.

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Sightlines


The sightlines of Prototype 4 massively increase the visibility of the user. The product is now intended for use above the ground, this will enable the Police and other members of the community to easily see who is within the space and what is going on within.

The Diagram below shows the new improved sight lines created bythe development in form, Prototype 4 .

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CAD


The image below shows the product in situation. The product has been assembled in a particular way to captalise on the modular intentions of the product. The way in which the product is sitting will produce a unique, interesting and above the ground space. The image includes a person for scale reference.

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Evaluation


Upon completing the design for Prototype 4, the product was reveiwed and evaluated. A re-occuring issue relating to the manufacture of the product was deemed to be a deciding factor in this prototypes success. At this point in the design process, the product manufacture was consindered in more detail, see Technicl section (DFM) for more details.

Things to consider and take forward

Follwing the consideraton of the design for manufacture of Prototype 4, a new set of form requirements was produced:

Product form must be manufacturable using existing manufacturing techniques.Manufacture of the existing form would result in large tooling and material cost.

The product form must incldue a support structrue to increase the rigidity and safety of the product. By including an intenal support structure the outside molded pieces can be molded using much less material and rely on the structure for supoort.

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Following the recent changes to the products form requirements, the design was re-visited and developed. Below shows the initial CAD model produce using Solidworks Surfaces and T-splines, the products new form can be split into 5 different modular sections.

Prototype 5

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Modular Design

the image to the right shows how the t-splines model was cut and split into 5 modular sections. the sections were then saved individually and taken into Solidworks for further modelling.

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To ensure each modular section could support the load of the users in use, the modular pieces were devloped further and designed to incorporate a steel support structure. The images below show some of the modular configuration possibilities of the 5 modular sections created in T-splines.

Prototype 5

100

0m

m

150

0m

m

The image above shows the overall heights on the assemble pieces. The smallest section reaches a height of 1000mm, whilst the biggest sections reach a height of 1500mm. As you can see, this prototype also adheres to the form requirements set out by the Police. (sight lines)

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Prototype 5 uses an internal steel support structure. The modularisation of the design and the inclsuion of the steel stucture allows the Top shell to be molded using a plastic polymer, in turn allowing for mass manufacture.

Prototype 5

The steel frame will be welded and assembled using square steel tube.

The top shel molding will attach to the outer frame through molded tabs and corresponding holes witinh the steel frame structure.

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Molded Tabs

The Top Shell Molding will rotationally molded, the mold will include the molded tabs for assembly purposes. The molded tabs allow the top shell to be located and fastened to the internal steel structure. The internal steel structure will increase the reliabillity and stuructural integrity of the modular pieces.

Prototype 4

The top shell molding will be produced with 4 molded tabs for attachment to the steel structure.

The Top Shell Molding will be bolted to the steel structure using standard size nuts and bolts.

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Attaching The Rubber

At this point in the development process, materials testing has proved 5mm EPDM rubber was the most suitable material of choice. See Tech section (Material Testing) for more details.

Prototype 4

Mechanism

Further reseach into the use of rubber as a seating material enabled me to design a suitable atttachment mechanism. The mechanism will form the link between the Top Molding Section and the rubber sheet material.

The images to the left show the mechanism and how it wouls be attached to the frame and the rubber.

The molding will be created with locating holes for fixing bolts.

The image above shows the number of attachement pieces that will be used to safely attach the rubber sheet ready for use.

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Human FactorsVoronoi Structure

At this stage in the development process, the decision was amde to test the rubber attachment and size of the seating and rubber it self on a full scale test rig. The testing rig ws deisnged and created using CAD software before being discussed and developed with an existing Rubber sheet specialist. AK rubber in Bishops Stortford were able to advise me before cutting and purchasing any rubber sheet.

The originial testing rig was designed to be attached in the same way as Prototype 5, after discussing the properties of the 5mm Rubber sheet and the loads the rubber will be exposed to, AK rubber suggested that the design was developed.

The images below show the two designs of the test rig and how they differ in function.

Full Scale Test

The images above show the development in the full scale testing rig, the re-design uses more material of the 5mm EPDM rubber sheet but will increase the performace of the seating pocket.

For more details on the construction of the Full Scale rig, please see Tech section

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Once the test rig was adeveloped and apporved vor construction the model was created. The rig was then used to conduct User Testing.

As previosly mentioned, the elctronics within the product idea will not be tested as it is an exisitng technology and participant time constraints.

Goals:

User should be able to ‘climb’ into the seating pocket within 20 seconds.

User should experience comfort when situated within the seating pocket.

User should be able to climb out of the seating pocket within 20 seconds.

Concerns:

Will user be able to successfully sit within seating pocket without failure or confusion?

Will user be able to sit within the seating in comfort?

Will the user be able to ‘climb’ out of the seating pocket using the rubber sheet as support? Will the rubber sheet support that?

Tasks:

Successfully navigate the seating pocket and ‘climb’ in.

Sit in comfort. (at this point the Wireless Bluetooth Technology would be used)

Climb out of the seating pocket.

Full Scale User Testing


Scenario:

The test will be conducted utdoors as the product will be used outdoors.

The product will be leant up against the wal at specific angles to find out the appropriate angle of use.

Participants:

The product will be situated within public space, the intended user is aged 17-22. However, due to transportation issues and the dificulties of acces to students aged 17-19 the test was carried out using peers aged 20-22. 3 participants were used.

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The test was carried out at 3 different angles, 35, 45, 55 degrees. The users when then asked to conduct the test at each angle. The results were as follows:

User Feedback

Results

35 degrees

45 degrees

55 degrees

To allow the collection and anlysis of data, the participants were asked to score the comfort at each angle from 1-10 (10 being the most comfortable).

Average Score of Participants

6

8

5

The pictures to the eft show the 3 participants sitting within the seat at different anlges.

After analysing the results, it was clear that an angle of 45 degrees was the most comfortale seating postion. Future Prototypes will be constructed to incorporate this data.

Evaluation

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During the test, the participants were asked to ‘climb’ in and ‘climb’ out of the seating pocket. This test allowed mt to observe the way in which the user would support them selves when climbing into the pocket.

Observastions

The images above show some of the observations in relation to climbing in and out of the seating pocket. One of the participants used the rubber sheet to support himself when climbing out.

This observation allowed me to confirm one of my original concerns, the rubber sheet was successful in supporting the users weight when

Observational Concern

During the test, one of the participants attempted to ‘climb’ into the seating pocket using their foot first. As the images above show, the participant was able to fit their foot through one of the Voronoi cut outs in the rubber sheet. This poses a potential hazard, the user could potentially become entrapped and endangered.

DESIGN CONSIDERATION. Voronoi cut outs to be smaller in size to combat this issue.

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Follwing the results of the Full Scale User Testing, the design was developed to incorporate the design considerations from User Testing. Prototype 5 was consturcted in Solidworks as a surface model to include the 45 degree angle of each seating pocket. The surface model was then placed into rhino to create th eT-splines model.

The image below shows the construction process of Prototype 5 within T-splines (Rhino).

Final Form

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Once the T-splines model had been created, the parts wwere saved as individual files and re-opened in Solidworks. Each modular section was then remodelled within Solidworks. The use of Solidworks at this stage allowed m to prepare each modular section for final form assembly.

The image below shows the finished pieces assembled in one of the many possible modular configurations.

Final Form

Bin Section

Internal steel Structure

Rubber with Voronoi cut outsHandles were added to

the modular sections

For the final form assembly additional features were added to make the product more suitable for public space use:

-For example the inclusion of the end section (bin section) allows the form flow into the ground and rounds off the form shape.

-The addition of handles will enable the user to easily climb the structure.

-For the final from assembly, each modular section was modelled with its internal steel structure.

-Visual queues were added to the largest seating pocket to show that the pocket is intended for two users to sit within it.

-Speaker Locations and speakers were added to the model.

Additions in Form Speakers

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Throughout the development process, the product has been tested and redesigned to include an internal steel structure. This structure is crucial to the success of the design, the image below shows the final form assembly of internal steel structure. The structure allows the top moldings of each section to be fastened to their correspong steel frame and create the final form.

The internal steel structure will be assembled this way on site before being bloted to the ground.

Final Form

Small Section

Angular Right Section

Angular Left Section

Large Section

Bin Section

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The Top Molding section of each piece was then added to the assembly and materials were applied. The inclusion of handles into the Final Formwill allow the user to climb the structure. The bin section included in the final form will allow the users to dispose of any waste easily. The bin section molding will also include a negative impression of the product logo and name, Nest.

Final Form

The molded bin section enables the form to flow beautifully into the ground, whilst also providing the users with a place to dipose of any waste.

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The inclusion of handles into the final design will allow the user to climb the structure with ease. To ensure the handles are appropriately designed, existing data was used to initally formualte appropriately sized handles for testing.The handles were then 3D printed using Makerbots and tested.

Goals:

User should be able to grip the handle in a comfortable postion.

User should initially grip the handle in the correct orientation. (intuitive design)

Concerns:

Will user be able to grip the handle with comfort?

Will user be able to initally pick up the handle in its correct orientation. (intuitive design)

Tasks:

Pick up the handle.

Handle User Testing


The handles above were designed to adhere with existing ergonomic data.

Participants:

The product will be situated within public space, the intended user is aged 17-22. However, due to transportation issues and the dificulties of acces to students aged 17-19 the test was carried out using peers aged 20-22. 3 participants were used.

70mm 150mm

40

mm11

2

3

11

2

3

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Handle User Testing

The test was conducted indoors, the picture below show the way in which the handles were picked and used by the participents. To enable the results to be evaluated the participents were asked to score the comfort of each handle out of 10 (10 being the most comfrortable).

Results

Hanlde 1

Handle 2

Handle 3

Average Score

4

8

6

Evaluation

After analysing the result of the handle user testing, the participents results indicated that handle 2 was the most comfortable handle to use. This handle will the general shape of all handles used within the Final form assembly.

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Visual Queue’s

Final Form

Visual Queue’s

To ensure the users are aware of the way in which the largest pocket can be used, I have researched and implemented Visual Queue’s. Within each Angular modular section, (largest size) the Voronoi cut-outs have been placed side by side. The use of the cut-outs within the other section clearly indicate space for one user.

The use of this visual queue will enable the users to understand that the rubber within this section is able to hold to users at one time.

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The images below show the Final assembly ofthe product in render form. The product has been place in situation and sits on an assembly of rubber flooring tiles.

Final Form

The render to the left shows the product and the way in which the users will use the product.

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Final Form

NEST Form Development

Documents

Transcript of NEST Form Development