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  • @JustinGiles unfortunately not.
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  • Could you send me a soft copy of this, I'd like to use it as an exemplar for my Design Technology class
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    A2 product design: coursework without hand drawn parts A2 product design: coursework without hand drawn parts Presentation Transcript

    • LORD WANDSWORTH COLLEGE58433OLIVER DERHAM 4017YEAR 2013PRODUCT DESIGN 9RM04
    • Research and AnalysisDesign Brief:Solution: My solution is to create some sort of floating shelf, which is all self-contained. The aim is to get all thecables in the interior of the product and if possible not have a need for a mains connection, although dependingon resources it may have to, but one cable for multiple items is still a huge improvement. On top of this Iunderstand people’s individual need for a unique product or a product to fit into an existing environment.Therefore, I plan to follow a similar route to IKEA in the fact that my product could have interchangeable parts sothat various colour schemes and layouts can be achieved or a different type of wood, for example.Situation:In our modern day lifestyle we all are likely to find ourselves in front desk. This is because 21st centurytechnology has created a more efficient workspace where computers are at the hub. In addition to computers,there are a number of peripherals, such as speakers, that enable to workspace to double up as a sort of mediacentre.Problems start when these technologies take over the workspace. This can create a lot of clutter from wiresbecoming entangled and pulling out involuntarily to paperwork and books being strewn about in random places.It can also cause problems with drinks tipping over when not sitting correctly on the desk. This therefore createsa hazard with the potential for liquids to react with the electricity in the wiring.Problems:• Loose cables and wiring can cause a hazard on the workspace• No space in the workspace to actually do any work or just to chill as having cables and wiringeverywhere adds to the mess that is already there from papers• Area can be messy, “an untidy space is an untidy mind”• As new technology is developed the number of peripherals can increase causing space to be usedup permanently forcing people to work in an isolated area• There are times where people need to relax and get out of the working mindset. Usually peoplelisten to music through speakers or watch TV or play video games. If this was attempted in theworkspace, again, the area would be further cluttered and rendered unusable• When people work, they tend to do so at a desk. This can be a hefty option that is hard to install inthe first place due to weight and size when bought• Affordable desks tend to be boring cubic shapesDesign Requirements:• Remove the problem of tangled cables• Keep everything out of the way of the workspace• Create an environment suitable for both working and relaxing• Be a potential media centre/hub• Be self contained• must be able to be packaged as a flat pack kit• Have interchangeable parts (like IKEA) to give a personalised product• Must come flat packed to reduce costs to the user from pre assembly and also allow parts to beinterchanged to the user’s preference• Must be able to fit in with existing environments• Installation must be fairly easy, i.e. wall mounted support arms must stay on the wall and notdamage or weaken the wall structure behind or box joints must fit properly• Must be able to hold the weight of at least 2 shelves of books and also a few peripherals (About 10- 15kg)• Must have a simple method of operating any electrical or mechanical systems• Screen and speaker systems must be compatible with different computer operating systemsExampleofanuntidyworkspacewithcablesandwiringintheway
    • Product AnalysisBookArc ProFUNCTION:THE FUNCTION OF THE BOOKARC PRO IS TO KEEP THE LOOSE WIRESASSOCIATED WITH THE MACBOOK PRO OUT OF THE WAY OF NOT ONLYTHE MACHINE, BUT ALSO THE DESKTOP SO THAT THE WORKSPACE ISCLEAR FOR OTHER USES. ANOTHER MAJOR FUNCTION IS TO KEEP THEMACHINE OUT OF THE WAY. THEREFORE BY KEEPING IT IN AN UPRIGHTVERTICAL POSITION IT CAN BE SLOTTED NEXT TO AN EXTERNAL DISPLAYRATHER THAN FLAT N THE MIDDLE OF THE DESK. IN DOING THIS IT ALSOINCREASES THE MACBOOK PRO’S HEAT DISSIPATION EFFICIENCY.PERFORMANCE:✴ IT IS WEIGHTED JUST RIGHT SO THAT IT IS NOT TOO CUMBERSOME, YETSTILL ABLE TO PROVIDE A FIRM BASE FOR THE MACBOOK PRO TO SIT IN✴ IT HAS A SILICONE HOLDER, THAT CAN BE CHANGED TO SUIT ANYSIZED MODEL OF MACBOOK PRO. IT ALSO PREVENTS ANY AESTHETICDAMAGE TO THE DEVICE.✴ 2 SILICONE HOOKS SIT UNDERNEATH TO ALLOW MULTIPLE CABLES TOBE THREADED THROUGH. THE SILICON IS NOT SOLID SO ALSO ALLOWSFOR SOME GIVE TO FIT THE AMOUNT OF CABLES NECESSARY.✴ THE ERGONOMIC CURVED SHAPE COUPLED WITH THE SLIGHTTHICKNESS OF ALUMINIUM PROVIDES A STABLE STRUCTURE TO NOTTOPPLE OVER AND ALSO TAKE THE WEIGHT OF THE MACBOOK PRO✴ SILICON FEET AT EACH CORNER STOP IT FROM SLIDING ACROSS DESKSAND ALSO STOP IT FROM DAMAGING THE DESK✴ THE THICKNESS MAKES IT DURABLE IN TERMS OF BENDING✴ THE ANODISED ALUMINIUM MATERIAL MAKES IT DURABLE FROMWEAR AND BIOLOGICAL DEGRADATION. IT ALSO KEEPS THE AESTHETICLOOK SIMILAR TO THE ANODISED ALUMIUM COATING OF THE MACBOOKPRO. THIS ALSO MAKES IT EASY TO WIPE CLEAN IF EVER NECESSARYMARKET:✴ THIS PRODUCT IS ONE IN A LINE OF UNIQUE TWELVESOUTH PRODUCTSPECIFICALLY DESIGNED FOR APPLE USERS. THEREFORE ONLYOWNERS OF THE MACBOOK PRO CAN USE IT. HOWEVER THIS GIVES ITA UNIQUE FEEL FOR THE OWNER MAKING IT A STAND OUT PRODUCT✴ ANYONE OF AGE THAT OWNS A MACBOOK PRO CAN USE IT, NOMATTER WHAT LINE OF WORK THEY ARE IN✴ DUE TO SPECIALISED CLIENTAL THE BOOKARC PRO SELLS ATAROUND £40.AESTHETICS/CHARACTERISTICS:✴ THE ARC SHAPE HELPS WITH GIVING A SIMPLE NAME. THESIMPLICITY OF THE PRODUCT ALSO HELPS WITH THEMANUFACTURING PROCESS AS IT ALLOWS THE METALSECTION TO BE MASS PRODUCED USING FORMER JIGS. THESILICON CAN ALSO BE REPEATEDLY INJECTION MOLDED.✴ ANODISED ALUMINIUM KEEPS WITH THE DESIGN OF THEMACBOOK PRO✴ AESTHETICALLY PLEASING TO LOOK ATQUALITY STANDARDS:✴ THE SHADE OF THE ALUMINIUM MUST BE SIMILAR TO THAT OF THEMACBOOK PRO (TESTED BY DIGITAL DETECTOR✴ THERE MUST BE NO DENTS✴ THE SILICON MUST BE FREE OF ANY FLASH✴ THE WEIGHT MUST BE SUITABLE TO NOT BE CUMBERSOME, BUT STILLWEIGHTY ENOUGH TO PREVENT THE WHOLE PRODUCT FALLINGSIDEWAYS.✴ THE ALUMINIUM MUST NOT CORRODE✴ ALL DIMENSIONS MUST BE CHECKED TO WITHIN THE SET LIMITS✴ 10 OF EVERY BATCH OF 100 SHOULD BE TESTEDSAFETY:✴ MUST NOT BE TOO HEAVY TO CAUSE INJURY WHILST MOVINGIT AROUND✴ EDGES MUST BE SMOOTH AND ROUNDED. THIS COULD HAVEBEEN DONE BY SANDBLASTING ITMATERIALS:✴ MAIN BODY- THE MAIN BODY IS MADE FROM ANODISEDALUMINIUM. THIS IS THEN LIKELY TO HAVE BEEN FORMEDON EITHER A MACHINE PRESS OR ON STANDARD ROLLERS✴ INSERTS- THE INSERTS ARE MADE FROM SILICON. THESEARE MADE USING AN INJECTION MOULDING PROCESS.✴ FEET- THESE ARE ALSO MADE FROM SILICON, WHICH HASBEEN INJECTION MOULDED✴ HOOKS- AGAIN THESE ARE SILICON SO HAVE BEENINJECTION MOULDEDLEVELS OF PRODUCTION:✴ DUE TO THE SIMPLICITY OF THE PRODUCT AND THE FACT IT HASVERY FEW COMPONENTS IT IS MASS PRODUCED. THIS IS ALSODUE TO THE FACT THAT THE SILICON PARTS CAN BE MADE SOQUICKLY AND CHEAPLY. THE ALUMINIUM HOWEVER TAKESMORE TIME TO PREPARE. THE ANODISING PROCESS CAN BEQUITE COSTLY DUE TO THE AMOUNT ELECTRICITY INVOLVED.THIS CONTRIBUTES TO THE OVERALL PRICE OF THE PRODUCT,BUT AS IT CAN BE DONE ON A LARGE SCALE IS NOT A HUGEISSUE ON COSTS AT THE END. THE ALUMINIUM COULDACTUALLY BE BATCH AS THE SHADE OF ALUMINIUM CAN VARYSLIGHTLY, WHICH IS WHY DETECTORS ARE USED TO MAKESURE THEY ARE WITHIN THE SET LIMITSHEALTH AND SAFETY:✴ RELEVANT RISK ASSESSMENTS FOR THEMANUFACTURING PROCESSES MUST BE CARRIED OUT BYTHE EMPLOYER. PARTICULARLY FOR THIS PRODUCT,COSHH IS VERY IMPORTANT DUE TO THE CHEMICAL ANDHIGH VOLTAGE IN THE ANODISING PROCESS AND ALSO THEMANUFACTURING OF NOT ONLY MATERIALS BUT ALSO THEWORKPLACE ENVIRONMENT.✴ EMPLOYERS MUST CARRY OUT DUE DILIGENCE TO ENSURETHAT THEIR EMPLOYEES ARE TRAINED PROPERLY IN THEIRJOB, TO ENSURE SAFETY AND EFFICIENCY✴ THE MANUFACTURER MUST OBSERVE THE OCCUPATIONALHEALTH AND SAFETY ACT OF 1970 (IN THE UNITED STATES)AS THE PRODUCT IS MANUFACTURED IN AMERICA.✴ PRODUCTION OF THE PRODUCT MUST FOLLOW THERELEVANT ISO STANDARDS.✴ FOR SHIPPING INTERNATIONALLY, THE PRODUCT MUSTALSO CONFORM TO THE RELEVANT STANDARDS, FOREXAMPLE IN THE EUROPE THE CE MARK IS REQUIRED
    • Product AnalysisBookArc ProStages of Production✴THE METAL:✴ ELECTROLYSIS -THE ALUMINIUM IS FIRST EXTRACTED BY THE SOURCE COMPANY BY THEMETHOD OF ELECTROLYSIS. UNLIKE MOST OTHER METALS IT CAN NOTBE OBTAINED THROUGH THE REDUCTION OF ITS OXIDE AS IT IS TOOREACTIVE. THE OXIDE COMES FROM MINING THE MINERAL BAUXITE (ITSORE). IN ORDER FOR IT TO BE AFFECTED BY THE PROCESS OFELECTROLYSIS IT HAS TO BE MADE MOLTEN TO ALLOW THE ELECTRONTO FLOW FREELY BETWEEN THE ANODE AND CATHODE. THEREFORECRYOLITE IS ADDED TO LOWER THE BAUXITE’S MELTING POINT ANDALSO TO HELP DISSOLVE IT FULLY. A DC CURRENT IS THEN PASSED THEMOLTEN BAUXITE. THIS CAUSES ALUMINIUM TO FORM AT THENEGATIVELY CHARGED CATHODE AND OXYGEN TO FORM AT THEPOSITIVE ANODE. AS OXYGEN IS THE LIGHTEST AND ALUMINIUM THEHEAVIEST, THE OXYGEN RISES TO THE TOP OF THE MACHINE ANDALUMINIUM SINKS TO THE BOTTOM, WHILST THE CONSTANT FEED OFBAUXITE REMAINS FAIRLY CENTRAL. AS THE MOLTEN ALUMINIUMFORMS IT IS TAPPED OFF INTO MOULDS, THAT ALLOW THE ALUMINIUMTO BE SOLD TO EXTERNAL COMPANIES.✴FORMING-WHEN TWELVE SOUTH RECEIVES THE ALUMINIUM BARS, THEY MELTTHEM DOWN INTO A FURNACE. THE MOLTEN METAL IS THEN POUREDINTO ANOTHER MOULD TO PRODUCE THE RIGHT SIZED MATERIAL TOWORK WITH. ONCE COOL, EACH PRODUCT IS THEN PUT UNDER THEPUNCH PRESS, WHERE THE DIE CUTS OUT THE RELEVANT SLOTS ANDGROOVES. THE PRODUCT IS THEN SAND BLASTED TO REMOVE ANYROUGH EDGES OR FLASHES. IT IS THEN PLACED UNDER ANOTHERPRESS. THIS PRESS BENDS THE PRODUCT INTO THE CRESCENT SHAPE. ITIS THEN READY TO BE FINISHED✴ANODISING-THIS IS A PROCESS USED TO INCREASE THE THICKNESS OF THENATURAL OXIDE LAYER OF THE ALUMINIUM. BY DOING THIS IT GIVES THEALUMINIUM AN INCREASED RESISTANCE TO CORROSION AND WEAR.THIS IS USUALLY USED TO PREVENT GALLING OF PARTS WITH THREADS.FOR THIS PRODUCT HARD ANODISATION HAS BEEN USED. THIS ISWHERE THE PART IS DIPPED IN AN ELECTRICALLY CONDUCTIVESOLUTION CALLED AN ELECTROLYTE (USUALLY AN ACID) AND ACURRENT IS THEN PASSED THOROUGH IT. THE ELECTRICAL CURRENTFLOWS THROUGH THE ELECTROLYTE AND INTO THE METAL. AS ITLEAVES THE METAL THE OXIDE LAYER BUILDS UP. IT HAS NOW BEENHARD ANODISED AND CAN EITHER BE LEFT AS A MATTE FINISH OR HAVECOLOURED PIGMENT ADDED, JUST LIKE THE 2012 IPOD TOUCH.Advantages DisadvantagesPure aluminium is formedAt the anode, oxygen is formed. This causes aproblem as the high temperature of the theelectrolysis cell causes the carbon electrodesto oxidise and burn. This burns them awayforming toxic gases, such as carbon monoxideand carbon dioxide. This means that theelectrodes have to be replaced regularly andthe waste gases dealt with safelyIs a successful extraction method of aluminiumIt is very costly, about 6 times more than theextraction process of iron due to the vastamount of electricity needed throughout theprocess✴THE SILICON PARTS:✴INJECTION MOULDING -SILICON PELLETS ARE FED INTO A HOPPER AT THE TOP OF THE INJECTIONMOULDING MACHINE. A HEATING ELEMENT MELTS THESE DOWN UNTIL LIQUIDIN VISCOSITY. THIS THEN FLOWS AROUND AN ARCHEMEDES SCREW. THESCREW IS THEN RAMMED FORWARD INTO THE MOULD THROUGH A HYDRAULICRAM ATTACHED TO THE REAR OF THE SCREW. A COOLING LIQUID USUALLYFLOWS THROUGH THE MOULD ITSELF IN ORDER TO INCREASE THE SCALE OFPRODUCTION BY REDUCING THE TIME WASTED WAITING FOR EACH COMPONENTTO COOL. THE SILICON PARTS ARE THEN EJECTED FROM THE MOULD, WHICH ISSOMETIMES DONE BY SPRING LOADED MOULDS.✴ASSEMBLY:THE SILICON HOOKS AND FEET ARE ATTACHED ONTO THE PROJECTIONS ON THEUNDERNEATH OF THE MAIN BODY. THESE TEND TO BE STUCK ON WITH ANEPOXY RESIN. THIS IS ALL THAT REALLY NEEDS TO BE DONE BEFOREPACKAGING AS THE SILICON INSERTS ARE PACKAGED SEPARATELY IN THEBOX TO ALLOW THE CONSUMER TO CHOOSE WHICH TO USE DEPENDING ON THESIZE OF THEIR MACBOOK PRO. WHEN PACKAGED, THE MAIN BODY IS IN A LDPESHEATH. THIS IS PLACED ON TOP OF THE SILICONE INSERTS. A COLOUREDCARDBOARD LAYER IS THEN PLACED OVER THE TOP, SO THAT ONLY THE MAINBODY CAN BE SEEN. THEN WHEN IN SHOPS THE BOX IS THE MAIN FEATURE.THIS MAKES IT LOOK LIKE A VERY HIGH END PRODUCT DUE TO THE QUALITY OFTHE CARDBOARD USED. ON TOP OF THIS A CARD SLIDER IS USED TO PREVENTTHE BOX FROM OPENING AND ALSO TO GIVE PRODUCT INFORMATION, SUCH ASTHE SPECIFICATIONS AND PICTURES.DIAGRAM OF ANODISATIONSILICONPACKAGING
    • Product AnalysisBedford Smart Wall-Mounted Speaker ShelfFUNCTION:THE FUNCTION OF THE BEDFORD IS PRIMARILY TO BE AN IPODSPEAKER SYSTEM. HOWEVER IT DOUBLES UP AS A FLOATINGSHELF STORAGE DEVICE. THIS HELPS KEEP LOOSE WIRESASSOCIATED WITH SPEAKERS AND ALSO THE SPEAKERSTHEMSELVES OUT OF THE WAY IN A UNIFORM MANNER.PERFORMANCE:✴ THE MAIN BODY OF THE SHELF IS MADE OF MANUFACTUREDBOARD. THIS MAKES IT A FAIRLY LIGHT, WHICH MAKES ITEASY TO LIFT DURING INSTALLATION AND REDUCES THETORQUE BEING EXERTED ON THE SUPPORT STRUTS HOLDINGTHE MAIN BODY IN PLACE.✴ THE SUPPORTS STRUTS ARE SHAPED SO THAT THEY SPREADTHE WEIGHT OF THE SHELF ACROSS THE FACE OF THE WALL.THIS PREVENTS DAMAGE THROUGH STRAIN WHERE IT ISATTACHED TO THE WALL.✴ THE MAIN BODY IS BASICALLY A LARGE FRAME. THIS ALSOHELPS SPREAD THE WEIGHT OF THE PRODUCT ACROSS THESUPPORT STRUTS.. IT ALSO PROVIDES REASONABLESTRENGTH TO HOLD BELONGINGS ON TOP OR WITHIN ALONGWITH THE SPEAKER SYSTEM✴ THE EXTERIOR CAN ALSO BE MADE IN MULTIPLE COLOURS TOSUIT ANY ROOM (PAINT/STAIN/VENEER)✴ THE IPOD CONNECTOR IS MODERN TO HELP AID THE AESTHETICLOOKMARKET:✴ THIS PRODUCT IS ONE IN A LINE OF SHELVING UNITS THATHELP KEEP OBJECTS OFF OF THE USERS DESK. IT IS MORE FORTHE OLDER GENERATION, FROM PERHAPS 18 YEARS ANDABOVE✴ THE PRODUCT IS MORE FOR USE IN ROOMS WHERE IT CAN BEAN AID TO PAPER WORK OR COMPUTER WORK TO FREE UPDESK SPACEAESTHETICS/CHARACTERISTICS:✴ SIMPLE SHAPE ALLOWS IT TO BE USED IN MOST TYPES OFROOM WITHOUT LOOKING OUT OF PLACE✴ VARIETY OF COLOUR SCHEMES AND SURFACE FINISHESALLOW IT TO BE BOUGHT BY A LARGER MARKET TO SUITTHEM.✴ SPEAKER DESIGN IS AESTHETICALLY PLEASING DUE TO ITSSIMPLICITY AND TIDINESSQUALITY STANDARDS:✴ THE COLOUR SHADE IS NOT A HUGE ISSUE AS CONSUMERSARE ONLY LIKELY TO HAVE ONE PER ROOM.✴ SPEAKERS MUST BE TESTED FOR SOUND LEVELS/FREQUENCIES TO MAKE SURE THEY WORK AND WILL NOTBREAK EASILY.✴ THE SUPPORT STRUTS MUST BE TESTED FOR STRENGTH ANDDURABILITY TO MAKE SURE THEY HAVE A LONG LIFE✴ SIZE AND WEIGHT MUST BE CHECKED TO MAKE SURE ITCONFORMS TO STANDARDS SETSAFETY:✴ ALL THE EDGES MUST BE SMOOTHED AND CORNERS ROUNDED✴ THE SUPPORT STRUTS MUST BE STRONG ENOUGH TO HOLD ITUP ON THE WALL✴ WIRING MUST BE TESTED (E.G. PAT TESTED)MATERIALS:✴ MAIN BODY- IS MADE FROM CHIPBOARD AND OTHER MANUFACTURED BOARD ASIT IS VERY AFFORDABLE TO BUY ON A LARGE SCALE, IT IS VERY LIGHT INCOMPARISON TO OTHER WOODS SO WILL NOT BE TOO CUMBERSOME AND CANBE FINISHED IN A VARIETY OF WAYS, SUCH AS VENEERING.✴ SPEAKERS AND SPEAKER COVERS- THE SPEAKERS ARE MADE OF VARIOUS PREMANUFACTURED COMPONENTS THAT CREATE THE DIAPHRAGM AND THEELECTROMAGNET BEHIND. THE COVERS ARE MADE OF A NYLON MESHMATERIAL TO ALLOW THEM TO STRETCH OVER THE SPEAKERS AND THEN FITTIGHTLY AROUND THEM✴ SUPPORT STRUTS- THESE ARE LIKELY MADE OF HIGH CARBON STEEL THATHAS BEEN HARDENED AND TEMPERED TO ALLOW RESISTANCE FROM THEWEIGHT OF THE SHELF A SUDDEN IMPACTSLEVELS OF PRODUCTION:✴ THIS IS LIKELY TO BE A KNOCKDOWN FITTING STYLE OFFURNITURE. THIS ALLOWS THE COMPONENTS TO MANUFACTUREDON A MASS SCALE, USING MOSTLY WORKERS NOT MACHINES,AS THEY DO NOT NED TO BE FITTED. HOWEVER, THIS IS MORELIKELY TO BE DONE IN BATCHES AS CUSTOMERS CAN ORDER THEPRODUCT IN COLOUR VARIATIONS TO SUIT THEM✴ THE CHIPBOARD COMPONENTS CAN BE IDENTICALLY CUT TO SIZEUSING JIGS✴ THE STEEL STRUTS CAN BE MADE USING AN AUTOMATEDEXTRUSION PROCESS. HOWEVER, DUE TO THE WALL FITTING IT ISMORE LIKELY THAT THERE IS ALSO AN ELEMENT OF FORGEWELDING NEEDED TO ADDED THE FIXINGS REQUIRE.DHEALTH AND SAFETY:✴ RELEVANT RISK ASSESSMENTS FOR THEMANUFACTURING PROCESSES MUST BE CARRIED OUT BYTHE EMPLOYER. PARTICULARLY FOR THIS PRODUCT,COSHH IS ALSO REQUIRED FOR THE MANUFACTURING OFNOT ONLY MATERIALS BUT ALSO THE WORKPLACEENVIRONMENT.✴ EMPLOYERS MUST CARRY OUT DUE DILIGENCE TO ENSURETHAT THEIR EMPLOYEES ARE TRAINED PROPERLY IN THEIRJOB, TO ENSURE SAFETY AND EFFICIENCY✴ THE MANUFACTURER MUST OBSERVE THE OCCUPATIONALHEALTH AND SAFETY ACT OF 1970 (IN THE UNITED STATES)AS THE PRODUCT IS MANUFACTURED IN AMERICA.✴ PRODUCTION OF THE PRODUCT MUST FOLLOW THERELEVANT ISO STANDARDS.✴ FOR SHIPPING INTERNATIONALLY, THE PRODUCT MUSTALSO CONFORM TO THE RELEVANT STANDARDS, FOREXAMPLE IN THE EUROPE THE CE MARK IS REQUIREDTECH SPECS:WHEN BUILT-HEIGHT = 400MMWIDTH = 1200MMDEPTH = 400MMWEIGHT = 19.2KGWHEN PACKAGED-HEIGHT = 400MMWIDTH = 1200MMDEPTH = 400MMWEIGHT = 19.2KG
    • Product AnalysisTHE MAIN BODY:FIRST, THE WOODEN BASE IS MADE. THIS IS DONE BY CREATING A HOLLOW BOX. THISIS USUALLY MADE USING MANUFACTURED BOARD THAT IS VENEERED TO GIVE THEREQUIRED FINISH, SUCH AS HEAVY MAHOGANY, WHILST KEEPING THE OBJECT LIGHT.A SIMPLE FRAME IS FIRST BUILT USING A LIGHT, BUT STURDY WOOD, SUCH AS PINE.AROUND THIS THE MANUFACTURED BOARD IS BUTT JOINTED AROUND IT AND THENEITHER GLUED OR TACKED IN PLACE. 2 OR MORE HOLES ARE DRILLED ABOUT 3/4 OFTHE DEPTH FOR THE SUPPORT STRUTS TO GO THROUGH. A DECORATIVE EDGE IS THENPLACED AROUND THE EDGES. ONCE BUILT THE SHELF CAN BE FINISHED IN A VARIETYOF WAYS, FROM LAMINATING TO STAINING OR PAINTING.SUPPORT ARMS:THE SUPPORT ARMS ARE MADE OF MILD STEEL. THEY CONSISTENT OF 2COMPONENTS- THE MOUNTING BRACKET AND THE TWO STRUTS. TO START WITH THEMOUNTING BRACKET IS CUT TO LENGTH SO IT IS JUST SHORTER AT BOTH ENDS THANTHE MAIN BODY OF THE PRODUCT. THIS IS DONE BY ONE OF 3 METHODS - CNC, PLASMACUTTING OR WATER JET CUTTING. THIS IS SO THAT THE MEASUREMENTS ANDPOSITIONING OF SCREW HOLES IS ACCURATE AND REDUCES MANUFACTURING TIMEBY REMOVING THE MANUAL LABOUR SIDE OF THINGS. 2 STEEL TUBES ARE THENMADE BY CUTTING THE TUBING TO 3/4 OF THE DEPTH OF THE MAIN PRODUCT. THENEXT STAGE IS LIKELY TO BEEN DONE BY A WORKER AS THE OVERALL PRODUCT ISMADE IN BATCHES AND CUSTOM ORDERS. THEREFORE, IT IS MORE COST EFFECTIVE TOPREPARE AND WELD THE STEEL TOGETHER. THE WORKER WOULD TAPER THE JOININGENDS OF THE STEEL TUB TO CREATE A CHANNEL FOR THE ... FEED. THERE IS APOSSIBILITY THAT AN INDENT COULD BE MADE ON THE MOUNTING BRACKET TO MAKETHE COMPONENTS FIT MORE SNUGLY. THE JOINING AREAS WOULD THEN BE CLEANEDTO REMOVE ANY GREASE OR OIL TO PREVENT ANY WEAK WELDS FROM OCCURRING.ONCE JOINED THE WELDS WOULD BE CLEANED TO REMOVE ANY SOOT AND THENPAINTED USING ....SPEAKERS:COME TO THE MANUFACTURER PRE BUILT. THEY ARE THEN INSTALLED INTO BOXES.THESE USE STANDARD BUTT JOINTS. HOLES ARE DRILLED FOR DOWEL JOINTS TO THEBASE AND TOP. THE TOP IS SIMILAR TO THE BASE, EXCEPT THERE IS NO HOLLOWSPACE. THE BACK IS JUST A SINGLE SHEET OF FINE GRAIN CHIP BOARD.WIRING:THE WIRING IS PRE DONE BY A COMPANY, WHICH THE MANUFACTURER OF THE SHELFHAS OUTSOURCED TO. ALL THE MANUFACTURER DOES IS ENCASED INMANUFACTURED BOARD, FITTING WITH THE REST OF THE PRODUCT. THE SPEAKERWIRING THEN LEADS OUT TO A MAINS SUPPLY CABLE FOR THE USER TO PLUG INTO AWALL SOCKETBedford Smart Wall-Mounted Speaker ShelfStages of ProductionAdvantages DisadvantagesCheaper than buying hardwoods as they areharder to source sustainably and are denserthan more common lightwoods, such as pineUser may feel that the product is “cheap tat”due to materials usedPossibility to have any aesthetic look due tolaminating or staining or paintingIt is very costly, about 6 times more than theextraction process of iron due to the vastamount of electricity needed throughout theprocessRecycling of wood to make boards is good forenvironment and sustainabilityBoards more likely to split under pressureSupport arms capable of holding a vastamount of weightThe wall it is mounted to may not be able totake the weight of the product or the turningforce put upon itDIAGRAM OF WALL MOUNTINGINTERNAL FRAMESHELF AND SUPPORT STRUTS
    • Product AnalysisSMARTdesk’s flipIT DuoFUNCTION: THE FUNCTION OF THE FLIPIT DUO IS TO TURN AWORKING ENVIRONMENT REVOLVING AROUND A DESKWORKSPACE INTO A MULTIPURPOSE PLATFORM. PRIMARILY THISIS TO HELP THE USER SWITCH BETWEEN PAPER BASED WORKAND COMPUTER WORK. I DOES THIS BY HAVING FLIP UPMONITORS THAT CAN BE CLOSED TO MAINTAIN A FLAT WORKINGAREA. IT ALSO KEEPS ITSELF SELF CONTAINED BY HAVING ALLWIRING UNDERNEATH THE DESK INCLUDING A ADDITIONAL MULTISOCKET FOR OTHER PERIPHERALS.PERFORMANCE:✴ IT IS DESIGNED TO BE COMPLETELY FLAT PACKED TO BE ASSEMBLEDBY THE USER, MAKING IT EASY TO SHIP✴ IT USES 2 STEEL WIRE STRAPS ATTACHED TO THE MONITOR FLIPPINGMECHANISM AND THE SLIDE OUT KEYBOARD TRAY, SO THAT WHENYOU PULL OR PUSH EITHER ONE THE SYSTEM MOVES TOGETHER✴ IT HAS A CABLE MANAGER TO KEEP POWER LEADS OUT OF THE WAYNEATLY✴ THE GAS STRUTS ARE CAPABLE OF LIFTING A 23” MONITOR BYTHEMSELVES✴ THE MONITORS ARE REALLY EASY TO PUT INTO THE OPEN OR CLOSEDPOSITION WITH MINIMAL EFFORT✴ THE MONITORS CAN BE ADJUSTED WHEN NEED FOR THE USER’S NEEDAS THEY ARE MOUNTED ON SWIVEL BRACKETS✴ THE MAIN BODY CAN BE CUSTOM DESIGNED TO THE USER’SSPECIFICATION SO THAT IT CAN FIT INTO ANY ENVIRONMENT, WITH ASTEEL FRAME OR WOOD VENEER, WHICH ALSO MAKES IT EASY TOCLEAN AND MAINTAIN✴ THERE IS AN INSET FOR A CPU, WHICH KEEPS IT OFF OF THE FLOOR ANDAWAY FROM BEING KICKED OR IN THE WAY✴ IT HAD ADJUSTABLE FEET SO THAT THE USER CAN MAKE THE PRODUCTLEVELMARKET:✴ THIS PRODUCT WAS PRIMARILY FOR THE EDUCATION MARKET, BUTHAS SINCE EXPANDED TO SUIT THE NEEDS OF BUSINESSES ANDANYONE REQUIRING BOTH DESK SPACE AND COMPUTER SPACE IN ASMALL AREA✴ TEACHERS OR GROUPS WORK THAT CAN USE THIS DUAL MONITORVERSION TO COLLABORATE WITH ANOTHER PERSON DIRECTLY✴ THE PRODUCT PRICE IS A QUOTE BASED ON THE REQUIREDSPECIFICATIONS OF THE USERAESTHETICS/CHARACTERISTICS:✴ THE CUSTOM DESIGNS ALLOW THE PRODUCT TO FIT IN ANYENVIRONMENT.✴ THE MECHANISM HELPS WITH GIVING A SIMPLE NAME.✴ THE MECHANISM OF THE PRODUCT COULD ALSO BE BOUGHT SEPARATELYTO FIT ONTO AN EXISTING DESK✴ DESPITE BEING MADE TO ORDER, JIGS WOULD BE USED FOR CLIENTS WHOJUST WANT THE MATERIAL CHANGED SO ALL THE COMPONENTS WOULDSTILL BE THE SAME. THIS WOULD CUT DOWN MANUFACTURING TIMES.✴ IT STILL LOOKS LIKE A DESK AND NOT OUT OF PLACE WHEN MONITOR ISDOWNQUALITY STANDARDS:✴ THE SURFACE FINISH MUST BE SMOOTH AND FLUSH SO THATPAPER WORK CAN STILL BE DONE✴ THE MATERIAL FINISH SHOULD BE PRECISELY WHAT THE USERHAS REQUESTED✴ THERE MUST BE NO DENTS✴ THE MECHANISM MUST BE ABLE TO OPERATE WITHOUTDAMAGING THE MONITOR✴ THE MOVING PARTS MUST NOT WEAR OR BREAK AFTER A SHORTPERIOD OF TIMESAFETY:✴ MUST NOT BE TOO HEAVY TO CAUSE INJURY WHILST MOVING ITAROUND WHEN FLAT PACKED✴ EDGES MUST BE SMOOTH AND ROUNDED. THIS COULD HAVE BEENDONE BY SANDBLASTING IT/ ABS COVERED (METAL) OR SANDING IT(WOOD)MATERIALS:✴ MAIN BODY- THE MAIN BODY IS MADE FROM EITHER WATERJET CUT MILD STEEL OR CUT MANUFACTURED BOARD WITHA PARTICULAR WOOD TYPE VENEER✴ FEET - THESE ARE MADE FROM STAINLESS STEEL SCREWSWITH AN ABS FOOT FITTED✴ MECHANISM - THE MONITOR AND KEYBOARD TRAYS AREALSO MADE FROM MILD STEEL. THE WIRE USED IS STEELAND THE SHARP EDGES ARE COVERED BY ANABS LININGLEVELS OF PRODUCTION:✴ DUE TO THE PRODUCT BEING CUSTOM THE LEVEL OF PRODUCTIONWOULD BE BATCH✴ MOST ORDERS WOULD BE FOR STANDARD MEASUREMENTS,THEREFORE JIGS CAN BE MADE TO CUT DOWN MANUFACTURINGTIME IN CONJUNCTION WITH CNC MACHINES✴ THE PRODUCT IS NOT ASSEMBLED FULLY IF MADE USING JIGS ASONLY ONE IN THAT BATCH WOULD NEED TO BE TESTED TO SEE IF ITFITS TOGETHER CORRECTLY. THIS ALSO CUTS DOWN ONMANUFACTURING TIME✴ MORE CUSTOMISED ORDERS WOULD TAKE A WHILE LONGER DUETO LARGER SIZES AND DIFFERENT SHAPES E.T.C. THIS WOULDREQUIRE MORE MANUAL LABOUR AND THEREFORE INCREASESUNIT COSTHEALTH AND SAFETY✴ RELEVANT RISK ASSESSMENTS FOR THEMANUFACTURING PROCESSES MUST BE CARRIED OUT BYTHE EMPLOYER. PARTICULARLY FOR THIS PRODUCT,COSHH IS ALSO REQUIRED FOR THE MANUFACTURING OFNOT ONLY MATERIALS BUT ALSO THE WORKPLACEENVIRONMENT.✴ EMPLOYERS MUST CARRY OUT DUE DILIGENCE TO ENSURETHAT THEIR EMPLOYEES ARE TRAINED PROPERLY IN THEIRJOB, TO ENSURE SAFETY AND EFFICIENCY✴ THE MANUFACTURER MUST OBSERVE THE OCCUPATIONALHEALTH AND SAFETY ACT OF 1970 (IN THE UNITED STATES)AS THE PRODUCT IS MANUFACTURED IN AMERICA.✴ PRODUCTION OF THE PRODUCT MUST FOLLOW THERELEVANT ISO STANDARDS.✴ FOR SHIPPING INTERNATIONALLY, THE PRODUCT MUSTALSO CONFORM TO THE RELEVANT STANDARDS, FOREXAMPLE IN THE EUROPE THE CE MARK IS REQUIREDTECH SPECS:WHEN BUILT-HEIGHT = 762MMWIDTH = 1524MMDEPTH = 762MMWEIGHT = 30KGWHEN PACKAGED-HEIGHT = 250MMWIDTH = 1524MMDEPTH = 762MMWEIGHT = 27KG
    • Product AnalysisSMARTdesk’s flipIT DuoStages of Production✴MAIN BODY:✴METAL-IT IS LIKELY THAT MILD STEEL IS EXTRUDED INTO SHEET MATERIAL. IT IS THEN CUTTO SPECIFICATION USING THE WATER JET CUTTER. AFTER THIS ALL OF THE CUTCOMPONENTS WOULD BE POWDER COATED. THIS IS WHERE AN ELECTROSTATIC GUNTURNS THE THERMOSET POLYMER POWDER INTO NEGATIVELY CHARGED PARTICLES.A POSITIVE CHARGE IS PUT ON THE MILD STEEL COMPONENTS. WHEN SPRAYED THISCAUSES THE PARTICLES OF THE THERMOSET POLYMER TO STICK TO ALL PARTS OFTHE COMPONENT WITHOUT LEAVING ANY UNTOUCHED AREAS. AFTER THIS, THEPARTS ARE THEN CURED BY HEATING IT TO AROUND 200OC TO CREATE A SOLID SKIN.THIS PROVIDES PROTECTION AND AN AESTHETICALLY PLEASING LOOK.✴WOOD VENEER-ALTERNATIVELY TO THE MILD STEEL, A WOOD VENEER CAN BE USED. THIS IS VERYSIMILAR TO THE MILD STEEL. FIRST MANUFACTURED BOARD WOULD BE CUT TO THESPECIFIED SIZES TO CREATE THE STRUCTURE. THE DIFFERENCE IS THE FINISH. APARTICULAR TYPE OF WOOD CAN BE REPLICATED USING THE VENEER TO MAKE ITLOOK MORE LIKE A CLASSIC DESK, WITHOUT ADDING A HUGE AMOUNT OF WEIGHTAND COST TO THE PRODUCT. I T COULD ALSO BE STAINED OR PAINTED AS IF IT WEREMADE FROM NORMAL WOOD PLANKS.✴ LID -THE LID IS MADE FROM ABS WITH AN ABS GUARD ON THE DESK. THESE ARE MADE BYINJECTION MOULDING. THE ABS PELLETS ARE DROPPED THROUGH THE HOPPER ONTOTHE ARCHEMEDES SCREW. HEATING ELEMENTS THEN MELT THE PELLETS UNTILLIQUID. THE SCREW IS THEN RAMMED INTO A MOULD USING HYDRAULICS. THE MOULDTHEN OPENS, EJECTING THE PRODUCT. THIS NEEDS MINIMAL FINISHING AS IT ISEXACTLY LIKE THE MOULD, WHICH HAS ALREADY BEEN FINISHED. HOWEVER, SOMEFLASH MAY NEED TO BE REMOVED. THIS IS USED AS IT IS DURABLE AND CANWITHSTAND THE CONTINUOUS USE OF OPENING AND CLOSING.✴MECHANISM:✴WIRE-THIS IS MADE FROM MILD STEEL. BY EXTRUDING AND DRAWING OUT A MILD STEELBLOCK MULTIPLE TIMES THE METAL TURN INTO A FLEXIBLE WIRE. BY ENTWINING ITWITH SEVERAL OTHER STRANDS THE WIRE BECOMES STRONGER AND THEN THESEENTWINED STRANDS CAN BE ENTWINED WITH OTHER ENTWINED STRANDS.THIS IS✴KEYBOARD TRAY-THIS IS ALSO MADE FROM MILD STEEL. HOWEVER, BEFORE THE POWDER COATINGPROCESS THE EDGES ARE BRICK PRESSED TO A 90O ANGLE TO PREVENT THINGSFROM FALLING OFF OF THE SIDESAdvantages DisadvantagesCustomised to userspecificationsCost and labour per unit goesupMild steel is relatively cheapdue to abundanceLow tensile strength for wire,but can be changed withadded chemicals/ processes-cost moreInjection moulding quick andcan produce parts on a largescalecost of running machinery forbatch production is high aspower required for heating andhydraulics costs a lot to runMany finishes can be achievedwith both the mild steel andwood veneerWood veneer could look toocheap aestheticallyManufactured board issustainable as it recycles offcut and requires less trees tobe cut downVery fibrous , so may need tobe treated before useCABLE TIDY:AGAIN, THIS IS MADE FROM MILD STEEL. IT ISBASICALLY A SMALL BOX, WHICH HAS BEENMADE BY BRICK PRESSING AFTER THESHAPE HAS BEEN WATER JET CUT. IT HAS ANOPEN SIDE FOR CABLE TO SIT IN. I T ALSOHAS PROJECTIONS FOR LONG CABLES TOWRAP AROUND.BRICK PRESSINJECTION MOULDINGFLIPIT IN USECABLE TIDY
    • OverviewEACH HAS IT OWN WAY OF ACTING AS A STORAGE DEVICE. THEY ALL HAVE VERY GOOD COMPONENTS, WHICH I WILL ATTEMPT TOINTEGRATE INTO MY FINAL PRODUCT, SUCH AS HAVING A MECHANISM AND BUILT IN SPEAKERS. THEY ALSO POINT OUT SOME BAD POINTSTHAT I WILL NEED TO OVERCOME TO CREATE A GOOD PRODUCT. FOR EXAMPLE, HAVING SUITABLE SIZE FOR IT NOT TO BE IN THE WAY ANDALSO KEEPING EVERYTHING SELF CONTAINEDTHE BOOKARC PRO IS VERY GOOD AS IT ISSMALL AND NOT VERY CUMBERSOME, YET ITPERFORMS AN IMPORTANT TASK OF FREEINGUP DESK SPACE AND MAKING HEATDISSIPATION FROM THE COMPUTER MOREEFFICIENT. HOWEVER, IT IS TOO SMALL FORANY LARGE SCALE EFFECT ON FREEING UPDESK SPACE AS THERE WILL BE MORE THANJUST THE MACBOOK PRO ON THE DESK ATANY ONE TIME. ITS DESIGN MAY BE USEFULAS A COMPONENT OF MY FINAL PRODUCTTHE BEDFORD SMART WALL-MOUNTED SPEAKER SHELFIS BETTER THAN THE BOOKARC PRO IN TERMS OFACTUALLY REMOVING ITEMS FROM THE DESKWORKSPACE, WHILST NOT GETTING RID OF THEM.PARTICULARLY HAVING THE SPEAKERS BUILT INREMOVES THE SPEAKERS THEMSELVES AND THETANGLED CABLES THAT FORM AROUND THE COMPUTER.IT CAN ALSO BE MOUNTED ANYWHERE AS IT COMES WITHA WALL MOUNTING BRACKET THAT THE SHELF ITSELFSLIDES ONTO. HOWEVER, I AM NOT A FAN OF THE PLAINOBLONG SHAPE WITH SKIRTING AS AN AFTERTHOUGHTAND WOULD LIKE THE IDEA OF THIS PRODUCT IN A DESIGNWHICH MAKES IT NOT “JUST” A SHELF WITH SPEAKERSTHE FLIPIT DUO IS THE BEST IDEA OUT OF THE THREE PRODUCTSAS IT ALLOWS THE DESK TO HAVE THE ABILITY OF BEING APAPERWORK DESK AND A COMPUTER DESK AT THE SAME TIME.IT ALSO KEEP THE CABLE SELF CONTAINED, WHICH IS WHAT ILIKE ABOUT THE CABLE TIDY DESIGN. I ALSO LIKE THE ABILITYTO HAVE IT EITHER METAL OR WOOD VENEERED TO SUIT ANYENVIRONMENT REQUIRED. ANOTHER THING IS IT HAS A SIMPLEWIRE MECHANISM, WHICH LIFTS THE MONITOR LID WHEN THEKEYBOARD TRAY IS PULLED OUT. THIS MAKES IT NOT “JUST” ADESK AND PUTS A BIT OF SIMPLE ENGINEERING INTO THEPRODUCT. ON THE OTHER HAND, IT WOULD MEAN REPLACINGANY EXISTING DESK WHERE IT WOULD GO, WHICH IS NOT WHATEVERYONE WANTS TO DO. IT ALSO DOES NOT HAVE ANY WAYOF KEEPING CABLES FROM SPEAKERS OR OTHER PERIPHERALSTHAT NEED TO BE ABOVE DESK LEVEL CONTAINED. HAVING AMOVING MECHANISM IS A GOOD IDEA THAT I WILL TRY TO USEIN MY PRODUCT TO HELP KEEP THINGS OUT OF THE WAY.Product AnalysisCONCLUSIONSUSTAINABILITYSUSTAINABILITYSUSTAINABILITYThe Aluminium is 76% recycled from offcuts and household goods.However, the amount of energy required for the anodising process is quitehigh, so is not very sustainable in that senseThe source of the pine comes from forests where 2 tress are planted forevery tree that is cut down. The mild steel... Mass production is moreefficient in terms of energy use.MDF is made from recycled off cuts. Water jet cutting does use a lot ofenergy and water, however the water is recycled through the machineseveral times.
    • User Group:• Customers using either the hotel rooms or function room or people needing a lesscluttered workspacePurpose:• Create a more useable workspace by keeping cables and peripherals out of the way. Itshould fit into existing environments with ease and also be self contained. Anotherpurpose is to also have drop down compartments and potentially a screen for storageand presentations.Product Specification:Form:• Must come in different styles, e.g. traditional woodor modern acrylic. The interchangeable parts allowthe user to achieve this to their own specifications• My client would like a cross between traditional Thaiand modern aesthetics• Must have the ability to be customised to the user’sneeds, in terms of colours and stylesFunction:• Must hold multiple peripherals• Must support the weight and number of bookstypically found on a bookshelf (about 15)• Be self contained• Be a product that can be used for presentationpurposes• Must be able to have interchangeable parts to allowthe user to adapt the product to their ownspecificationsUser Requirements:• Must come flat packed to reduce costs to the userfrom pre assembly and also allow parts to beinterchanged to the user’s preference• Must be able to fit in with existing environments• Installation must be fairly easy, i.e. wall mountedsupport arms must stay on the wall and not damageor weaken the wall structure behind or box jointsmust fit properly• Must be able to hold the weight of at least 2 shelvesof books and also a few peripherals (About 10 -15kg)• Must have a simple method of operating anyelectrical or mechanical systems• Screen and speaker systems must be compatible withdifferent computer operating systemsPerformance Requirements:• If battery operated, the life of the battery mustexceed about 6 months of regular use• Drop down compartments should last (on battery) anaverage of 10 up and down movements a day. Thismeans the pulley system will have less maintenanceneeds• If the design includes a mechanical system, it must beable to support a minimum load of 5kg. This couldextend to also supporting a screen if possible, in whichcase it should be able to support a minimum load of10kg• There must be some way of getting to the electrical ormechanical system for maintenance needs• If support struts are used (attached to the wall) theymust be tested for strength and durability to be surethey can support the full load of the shelf• Shelf must not wobble.• Must not exceed a shipping weight of 30kg• The structure must incorporate a speakers system.Materials and Components:• Any support struts (attached to the wall) must betested for strength and durability to be sure they cansupport the full load of the shelf• Any support struts must have a method of attachingto different wall types, e.g. brick or dry wall. Thisshould help prevent the damage or weakening of walls• Any wood must come from reliable and sustainablesources• Any plastics being used must have been recycled ifpossible• All materials should be found locally in relation to themanufacturing location• The main body must be light, therefore if wood is usedit is likely to be made of a manufactured board thathas been laminated to give a real wood feel• Metallic components should ideally be anodised andpossibly pigmented (this increases durability)• Must last between 5 and 10 yearsSize:• Should be of a size (when in flat pack form) that canbe packed into standard cardboard boxes and takenhome by the user• When flat packed, the weight of the boxes should notexceed 30kg• For my client’s purposes, the product should be aboutthe size of a 30” or 40” screenSafety:• All edges and corners must be rounded to preventinjury• The initial weight should not exceed 30kg forinstallation purpose• In flat pack form, it should be ergonomicallypackaged for ease of transportation• Individual components must be easy to lift and installto help prevent injury to the user’s back when movingcomponents• All wiring and electrical supplies must be PAT tested• There must be no significant gaps in the drop downcompartments to trap fingers in• Any support struts must be tested for strength anddurability so the shelf doesn’t fall onto someoneQuality:• All materials and components, from the main body toadhesives and fixings, must be subject to BritishStandards testing and also safety standard tests.• Quality control must be implemented throughout toensure that each components is of the highest qualitybefore sales• Must be no blemishes or webbing on acrylic sections• The wood must be flush where there are any jointsand also flush against the wall it is mounted on toprevent wobbling• All finishes, be it varnish or paint must be to thehighest standardScale of Production:• To start with production will be on a batch scale andpotentially will increase to mass in the future• Jigs can be created to increase production efficiencyand also to create the interchangeable parts with theclient’s specifications to vary it from what is sold toother consumers• Standard fitting should be used where possible, toreduce overall costs and to not overcomplicate theproduct for the user’s assemblyCost:• My product should retail at around £200 - £300 tomy client• The product should not be overly expensive• As my client is part of the hospitality industry theprice of the product will be slightly higher than thatof the average consumer as the components will bemade to his specifications• The materials will be sourced at reasonable prices• The components will be sold as separate items,however they are likely to be bought as a set• Depending on the total cost of materials, I would beretailing the product at about 175% of the materialcostsDesign Brief:• To design and build a product for use in a hotel or office space to create a tidy andmore efficient workspaceClient:• Matthew Keenlyside, General Manager of The Chilli PadManufacture:• The Products should be created so that it flat packed.This allows the user to easily transport it to alocation . Then they can assemble the productthemselves with ease. This reduces the time needed tocreate each product as it removes the assembly stagefrom the production line. By doing this the number ofunits that can be shipped can increase. This also addsto the advantage of IKEA styled components that canbe bought and assembled together at the users willUse:• The components will be rigorously tested before sale.However, if a part does break, components will beavailable as they will be made on a mass scale and thecomponents will be sold as separate items to allowthe function of interchangeable partsEnd of Life:• As the majority of materials will have been recycledthey could be recycled again. The electrical parts willbe in an isolated section of the product. This lets theuser dispose of the electrical components separatelyin a more safe and sustainable manner
    • Second Contact with ClientI have sent Mr Keenlyside a small questionnaire via email to get more specific information onwhat he wants. Below is a screenshot of the document he sent back./9/12
    • Third Contact with ClientHaving received Mr Keenlyside’s completed questionnaire I brainstormed his ideas. I created amindmap and developed some of his major points. In doing this I have started to create a fewimproved design ideas, which I have now shown to him. He said he would look over them and get intouch soon after./9/12
    • Designs 1 2 3 4 5 6Performance 4.5 4.5 3 4 3.5 5User 5 3 3 4 3.5 3Materials and components 4.5 4.5 4 4 5 3.5Safety 3.5 4 4.5 5 5 5Quality 5 4.5 4.5 5 5 3.5Client 5 4 4.5 2 4 4.5Total 27.5 24.5 23.5 24 26 24.5InComparisonTo1 2 3 4 5 61 X• Very Open in comparison• larger space for presentational pieces• Too large for existing environment• Hard to mount onto soft dry walls• No screen or speakers• Free standing makes it easy toposition and move• Can be quite heavy as it doesn’t needto be wall mounted• Could be overweight?• Does not have a screen• Speakers are the focal point• “Just” a shelf with a speaker• Easy to wall mount or free stand• No real effect on market area• Very open look• Fewer components makes it easier toship and assemble• No mechanical parts to fiddle with• Not everyone has a projector• Lighter as there is no LCD screen• Space for presentational pieces• No electrics needed for drop downsystem therefore no mains socketrequired near unit2• Self contained• Nice modern design with traditionalstyles integrated• Customisable• Screen and other peripherals kept outof the wayX• Not as larger• Can be used for media presentationsand storage not just objects• has speakers and screen• Can hold few items• Nothing special about iit• Has a speaker• Easy to mount anywhere• Very open look• Fewer components makes it easier toship and assembleLooks better due to simplicity• Self contained• White screen• Slightly easier to mount anywhere•3• Modern way of keeping things out ofthe way without need for a drawer orputting them on top• Less cumbersome• Does not take up bar space• Can hold more peripherals• Can showcase many products• Permanent• Focal point of environment X• Can hold few items• Nothing special about iit• Only has a speaker• Modern shape• Simple assembly• Very open look• Fewer components makes it easier toship and assemble• Lighter and less cumbersome• Better presentational/ storage space• Modern appeal to drop down feature• Harder to mount on all due to weight4• Can hold multiple peripherals• Has both a screen and a speaker• Modern appeal to drop down feature• Harder to assemble/ install due tonumber of components• Can hold multiple peripherals• No speaker• traditional wooden aesthtics• Self contained• More cumbersome• Harder to find space• Has speakers and a screen X• Very open look• Has speakers• Has more use potential• More of a focal point• Has a white screen for projections• No speaker• Modern appeal to drop down feature5• Similar shape• Not as open looking• Has a screen• Would look les cluttered due to dropdown compartments• Can hold more peripherals• Harder to wall mount due to size• Overlay large• Heavier• Very cumbersome•Easier to position as it doesn’t need tobe mounted• Very plain looking• Not as open• Can hold few items• Nothing special about iit• Only has a speaker• Modern shape• Simple assembly X• Not as open• Has a screen aswell as a speaker• Harder to wall mount due to weight• Would look less cluttered due to selfcontained drop down shelf6• Does not require projector• Heavier due to screen• Mechanical components harder tomaintain without knowledge ofcomponents• Can hold multiple peripherals• No white screen or speaker• traditional wooden aesthtics• Does not look as modern• Not self contained• Very cumbersome•Easier to position as it doesn’t need tobe mounted• Very plain looking• Easier to find space for• Does not have a white screen• Speakers are the focal point• “Just” a shelf with a speaker• Easy to wall mount or free stand• No real effect on market area• Very open look• Fewer components makes it easier toship and assemble• No mechanical parts to fiddle with XEvaluation Matrix
    • I have chosen to go with the simple 2:1 ratio pulley as the Movement/Velocity ratio is also 2:1. Thismeans the length of string required to lower and raise the load is not too long as the length moved by theactuator will be half of what the load will move. Also, the actuator I will be using will have more thanenough force to be able to lift the actual maximum load of 8kg as the 2:1 ratio also means that theeffort to load ratio reverses so that twice the amount of effort will be required to lift the load. The pulleystill will still have a vital role of creating a system that allows the actuator to act on both loads at oncenot just one in the most efficient way./ :tantanMovement Velocity RatioDis ce Moved by LoadDis ce Moved by Effort:tanEffort to Load RatioLoadEffortForce Required toMove a Cons t Load=:If m 1=:m Ratio21211 2`= =:If m 1=..: Ratio0 220 663 1 3`.=:m Ratio31311 3`= =:If m 1=..: Ratio0 220 884 1 4`.=:m Ratio41411 4`= =..: Ratio0 220 221 1 1`=:If m 1=:m Ratio1111 1 1`= =DEVELOPMENT: PULLEYSYSTEMFrom my development I have encountered a few issues, which I will need to address for my final product:Problems SolutionsThe material used for the rope has atendency to slip on the wheels, whichcauses extreme wear, thus shorteningthe product life of the pulley.I will prevent slippage on the wheels byroughening up the wheel surface. As aresult I will also have to find a ropematerial, which can grip onto this andalso be resistant to prolonged wearThe rope can come off of the wheelsand drop the loadI will have to create some sort ofcomponent that acts like a guard andkeep the rope on the wheel at all timesFor my drop down compartments Idecided to test out a method of usingpulley ratios to reduce the force and/ordistance required from the poweringmechanism to lift and drop the loads
    • DEVELOPMENT: ACTUATOR ANDPOWER SUPPLYT Mg MaT mg ma- = -- =( )M ma M mg M m0>`-= +-.( . )( . ).aa ms9 8176 5 876 5 87 95 2=+-= -( )( ) ( )( )( )Mv mv mgh MghM m v M m ghv ghM mM m21212122 22+ = - -+ = -=+-E EK PO O= -. .( . )( . )..VVV ms2 7 95 0 2276 5 876 5 82 841 68 1# #=+-== -...F mgFF NForce required from actuator N8 9 8178 4878 48#` 2===Therefore this actuator will be suitable enough for use. The load I have specified will also mean that the actuator willhave a long life as it is only 11% of what it is capable of pulling. An issue I may encounter is that the compartmentswill move far too quickly so I will have to limit the force of the actuator by reducing the current flowing through thecircuit. I also have some leeway with the load I can place on the system as is is capable of heavier loads.The power supply I intended on using was a YUASA 7ah battery.This was to keep the product self contained so it would not need amains cable. However, this would on be sufficient enough to keep thecompartments going up and down 10 times a day for a year. Thismeans that having a screen as my client requested, would mean woulddrain it too quickly. I will therefore resorts to a mains supply as it isstill only one cable to power the unit.The current I will require will be less than 1 amp( )T ma mgT m a g= += +( . . ).TT N8 7 95 9 81142 08= +=In order to move my pulley system I have decided to test out an actuator. I calculated some keymeasurements required to decide if it was suitable and how I would need to operate itT Tension in ropeM Maximum mass lifted by actuatorm Mass of object on end of pulleysg Acceleration due to gravitya Acceleration due to gravityEK Kinetic energyEp Potential energyM Maximum mass lifted by actuatorg Mass of object on end of pulleysa Acceleration due to gravityh Height/ distance movedV VelocityF Forcem Mass of object on end of pulleysg Acceleration due to gravityT Tension in ropeM Maximum mass lifted by actuatorm Mass of object on end of pulleysg Acceleration due to gravitya Acceleration due to gravity
    • DEVELOPMENT: SUPPORTSTRUTSFor the support struts I tested two welding techniques on two different types of strut. The first goesthrough a hole in a product to hold it on a wall and the other acts like a shelf and lets the shelf sit on top of itForge Welding MIG WeldingFor this I use braising. To do this I first cleaned up the two surface to be joined using emery clothof different grades and then rinsed clean. I then tapered one end of the cylindrical to create a channelfor the braining rod to fill in. To create the join I had to heat both materials at the same time evenly.Once red hot I could then move the braising rod across the channel to fill it in and the joint is made.Doing this, I had a few issues, which have made me turn away from this process.๏ Both materials must be the same thickness, where I may need the wall bracket slightly thicker inreality๏ The join was not clean as there was a lot of soot๏ The join ended up having a lot of holes in as a cylindrical shape is hard to join as heating itevenly is very hard๏ It is extremely hard to create the joint without blowing a hole through the materialFor this I used MIG welding. I found this to be much better than braising. To start with I cleanedup all the joining surfaces using various grades of emery cloth as before and then tapered the joiningedges. To create the join I first lined up all the components into the position I wanted them to befixed using magnets. I then attached a to the wall bracket piece to ground it to prevent meelectrocuting myself. When I fed the steel wire through the gun and I pull the trigger electricalcurrent is flowing. When I touch this wire onto the components, the electrical circuit is completed and aspot weld is created, much like the effect of solder, but much stronger. A carbon dioxide - Argon mixis also flowing onto the weld area, which prevents soot from forming on the weld, making it clean. Thisis what I will be using for my product because of the following:๏ The weld is very strong, especially in comparison to my braising welds๏ It is much easier to do as the materials don’t need to be the same thickness or heated and istherefore very quick to do๏ The weld is clean and does not need much finishingA few issues I did encounter were:๏ You have to use the precise settings for heat, wire feed and power going through the equipmentotherwise pigeon droppings form๏ You must not rush the weld๏ Both materials must be cleaned and prepared properly for the weldThis support is also very strong dueto the diagonal support. However, Idon’t think I will use this as it willtake more time to make sure thatthe components are the correctlength and when welded are at thecorrect angles. Also, it does notlook as aesthetically pleasing asthe cylindrical support as it doesn’tgive as much of a floating effectThis support is strong due to theMIG weld. However, it may have atendency to break with the addedtorque put upon the weld with theunit weight. It is also harder to welda curve. However, it does keep theunit self contained as it is hiddenfrom view
    • DEVELOPMENT: JOINTS FOR MAIN BODY ANDCOMPARTMENTSFor these joints I decided to test comb joints and dowel joints. This is to make sure that I havesturdy joints that will not move or break under various loadsComb Joints Dowel JointsFrom my testing I have found that comb joints are the best joints to use. This is because of thefollowing:๏ They are strong against forces across the joint due to the comb structure๏ They can withstand a large amount of force and therefore load due to the comb structurecombined with wood glue๏ It has good torsional strength๏ It looks aesthetically pleasingHowever, these can take a lot of time and effort to make as the joints have to be cut veryaccurately in order to fit snuggly and look neat. This could be solved by creating a template or jigto make sure all of the pieces fit together properlyFrom my testing I have found that dowel joints could be used but are not the best option. This isbecause of the following:๏ They are fairly simple to make as all that is required are holes to be drilled and pre madedowels to be fitted๏ Less material is wasted in comparison to comb joints๏ Good for flat packing as it is really easy to assemble without worrying about whether each picehas been fitted at right angles as it fits into place by itselfHowever, a template or jig can still be used as a precaution to make sure all the pieces will fitcorrectly. Also, the aesthetics after assembly make it look like a standard butt joint, which will makethe user feel as if the compartments were an after thought with a weak joint.Distance, smmSurvival?400 ✓600 ✓800 ✓1000 ✓1200 XResultantForce of Masson JointSpeed of Massat MaximumToleranceTorque PlacedUpon the JointAfter ImpactMomentum ofMass atMaximumToleranceV U AS22= +.V 2 9 81 1# #=.V ms4 43 1= -p mv=. .p 1 474 4 43#=.p Kgms6 53 1= -F ma F mg`= =. .F 1 474 9 81#=.F N14 5=M FS=. .M 14 5 0 095#=.M Nm1 38=ResultantForce of Masson JointSpeed of Massat MaximumToleranceTorque PlacedUpon the JointAfter ImpactMomentum ofMass atMaximumToleranceDistance, smmSurvival?400 ✓600 ✓800 X1000 X1200 XV U AS22= +. .V 2 9 81 0 6# #=.V ms3 43 1= -p mv=. .p 1 474 3 43#=.p Kgms5 01 1= -F ma F mg`= =. .F 1 474 9 81#=.F N14 5=M FS=. .M 14 5 0 095#=.M Nm1 38=
    • DEVELOPMENT:SIDE SPEAKER/STORAGECONTAINMENT MATERIALI started with a pre formedplywood laminate to use as aformerFirst I tried putting theformer in a vice and using aheat gun to form the acrylicstrip around itThis did not work as planned as theacrylic would not hold its shapeduring the moulding as it cooled downtoo soon. This is because it is far tohot to touch when heated to a pliablestate and also because it is athermoplastic that returns to itsoriginal shape when heated.I tried the process again, but I clamped down oneend. This allowed me to heat up the materialwithout worrying about its position on the former.When pliable I quickly pulled the material over theformer. The result was better than before, howevera significant crack occurred due to the force neededto form it and the time it takes for the material tocool down and whether the material has beenheated evenlyIn order to heat the acrylic strip evenly Idecided to try the strip heater. This workedmuch better as it had a similar effect to avacuum former heating element.The one issue I had was that bubbles formedeasily in the centre of the acrylic as thesection directly above the heating elementtended to heat up much quicker than the restof the acrylicOnce pliable I placed the acrylic into theformer’s mould instead of the former. This wasbecause it is much easier to apply the pressureon the pliable acrylic evenly to form the desiredshape rather than try to force it into shape asit cools along the former.The end result is muchbetter!For the side pieces, I decided to test out different methods of formingthe acrylic to the correct shape
    • Transparent acrylic cover just to add some modern depth to the top so it isn’t just plainMounting bracket is two MIG welded mild steel tubes on a mild steel strip. Maybend as a result of the torque put upon itDEVELOPMENT: INITIAL CAD DESIGNS12Comb joints along edge. Very strong, but maywobble with mechanism attachedTotal acrylic speaker shellfor lightness and durability.The speaker is mounted ontoacrylic mounting stripsStained pine mounting board (biscuitjoined) for screen or space for shelfDarker contrasting wood(stained pine or teak) shelfin housing jointMild steel frame for stand, plastic dipcoated or sprayed with chrome paintStacked speaker style with graduating radiiSquared edge to add a modern twist by addinga sharp angular look to a curved shape. Madefrom acrylic with an MDF frame insidePerforated steel sheet speakercover, sprayed with chrome paintStained pine mounting board (biscuit joined) for screen. Will have holes for wires e.t.c.Comb joints used for their good torsional strength anddurability. This is good as the compartments and unit weight willput a lot of stress and strain on them3 compartments, 2 smaller ones for remotes e.t.c., one larger one for a laptop and wiring to screen
    • FrontViewIsometricViewCommentFrontViewIsometricView Client CommentThis design looks very modern with itsperfect semi circle design. It is easy to formdue to this simple shape, that has no trickyangular areas that may not have beenformed well otherwiseThis design will make the total unit lengthlonger than necessary due to the flatplateau.This looks stylish, but addsunnecessary weightThis was based on some of my clientssuggestions on my initial ideas. It keeps theunit looking very angular, which somepeople like, but in this case may be toomuch for the productDEVELOPMENT:SIDE SPEAKER DESIGN (1)Design1Design2Design315 x 15 x 340, acrylic stripto mount speaker ontoAcrylic side to mount ontomain unit made from lasercut acrylic and butt joinedwith Tensol-1215 x 15 x 40 acrylic block tomount speaker ontoCentre hole, diameter 70mm, toallow bell of speaker and its wiringto go behindSemicircular acrylic, radius 170and 5mm thick to mount the mainspeaker body onto The edges can be joined to themounting strips in the main shell ofthe speaker using Tensol-12 to fixit in place with easy as it is thesame material being joinedSquare cut out 50 x 50for wiring to feed to mainunit bodySquare cut out 50 x 50for wiring to feed to mainunit body
    • DEVELOPMENT:SIDE SPEAKER DESIGN (2)
    • IsometricViewCommentIsometricViewClient CommentThis design is most common amongstfloating shelves. It is particularly appealingas it will be hidden from view. However,welding the tubing would be hard and theweld may not form properly and thereforebe weak and potentially cause the unit tofall and smash to piecesThis design is likely to be the simplest tocreate, due to the angular nature of thecomponents to be welded. I would preferto use this as it would help support theforce caused by the unit and the turningforce placed upon it as a result. However itwill be on show in its current state, so Iwill need to adapt it if I am to use itDEVELOPMENT:MOUNTING BRACKETDesign1Design2Slot cut into back of main unit60 x 300 x 5. This allows theangled bracket to be used. It alsohelps support more weight from theturning force caused by the unithanging off of the wallUnit slides onto bracket It remainsseparate to allow the user toposition them so that it can be level4 3.5mm countersunk holes to fixebracket securely onto wall and makesure the unit sits sits flushMild steel MIG welded
    • ViewsCommentViewsClient CommentThis design makes efficient use of spacewith the screen using only what it needs interms of depth.This allows a larger spaceto be used for the drop downcompartment. It is very simple to assembleas the components fit together like a jigsaw.The wide slot on the side is also veryuseful as it means wires are not beingforcefully crammed into place when thespeaker is attached. However, the weightmight be an issue, particularly because ofthe distance the unit comes off of the walland therefore the torque applied to thesupport struts.DEVELOPMENT:MAIN BODYCrossSectionIsometric14mm pine block, to mount screenonto securely without the risk ofbreaking it14mm wide and 3mm deeprouted groove to keep thepine mounting block inplace and to prevent anywobble from occurring3mm birch ply will be mounted on4 mitre blocks to seal the back,whilst keeping weight to a minimumComb joints for maximumstrength to weight ratioMounting block in place, wiringfeeds through slots cut into it50 x 50 slots cut into both side pieces before joiningto main body for speakers to be mounted and connectedMitered blocks of pineBirch ply backingPine screen mount
    • DEVELOPMENT: DROP DOWN COMPARTMENTSIsometricView FrontViewCommentIsometricView FrontViewClient CommentBased on my clients initial ideas, this design conforms to modern environmentsnaturally, as it replicates the exiting have of having a TV screen with speaker unitson either side. It is also good as it separates items, so the user can have remotecontrollers in one section and menus in another. However, after some thought, toapply a mechanical mechanism to this would be quite tricky and also unnecessaryas the actuator can support 75kg by itselfThis design improves upon the idea of the product being “clean and neat” whilstbeing self contained. It is very open so does not impose itself too much.Theshelves are also good in the fact that they are only joined on 2 edges, whichsimilarly to the main unit, gives the unit even more of a tidy, self contained feeling.It is also easier to feed wires to particular gadgets as everything is in a singlecompartments, therefore the slots only have to be in one placeDesign1Design27 x 100 x 5 routed slot cut out of pine side for shelfComb joints for maximum strength to weight ratio7mm thick pine sides25mm radius circular holes through pine back piece. This is to keepwires out of the way and keep them within the main unit bodyLaminated birch ply shelves. This is to keep them light, but also to makesure that they will be strong and durable enough for continuous useOverall look
    • IsometricView FrontViewCommentIsometricView FrontViewClient CommentThis design in slightly complicated, but utilises the mechanical idea behind the upand down movements. It also will be able to support a vast weight due to the 2:1ratio of the pulleys.The use will hopefully see this as a well made piece with thisincorporated into the unit. However, by doing this the rope used with the pulleyshas the potential to catch on other parts of the mechanism and therefore notwork.This design is appealing due to its simplicity.After some thought, to apply amechanical mechanism to this would be quite tricky and also unnecessary as theactuator can support 75kg by itself. So in terms of efficiency of space and buildtime, this idea is would be the better choiceDesign1Design2 DEVELOPMENT:DROP DOWN MECHANISMPine bottom, with a smaller piecemounted on top to make thebottom flush when closed and tosit in a groove on the main bodySimple rebate/housing joint witheither birch ply or thin pineSide pieces sit onedge of top piece. Layout of mechanismDrawer rails allow themechanical unit to slide outfor easy access maintenanceText
    • Acrylic speaker shell formed using heat gun and jigand then fits over laminated birch ply frameBirch ply wood backing with slots for mounting bracket cutPine screen mountDEVELOPMENT: FINAL CAD DESIGN - EXPLODED VIEWSRouted slot for end of actuator to be fittedRouted rebate for housingjoint of screen mountStained pine/ teak shelves, housing joinedto two sides of the compartment frame 2 holes cut with a circular saw forcables and wiring to fit throughMitred pine to help support theback pieceSlot cut out to feed wiring tospeakersSlot cut out to allow mountingbracket to fit all the way throughSlot cut out using band saw tofeed wiring to speakersSand casted aluminum mountingbracket for actuatorPerforatedsteel sheetwith chromepaintBirch Pywood speakermountLaminated plyinternal speakerframePine side comb jointed totop and bottom pieces MIG welded mild steel bracket with black metal paintScrews on to mitredpine supports
    • DEVELOPMENT: FINAL CAD DESIGN - COMPONENT VIEWSCOMPARTMENTSIDEISOMETRIC - BACKBACKCOMPARTMENT - ANGLED TOPFRONTTop - Actuator endpushes through and isheld in place with ashort mild steel dowelUnderneath top - Actuatorsits in routed slotFRONT - ANGLED
    • Manufacturing Plan: Main Body - Outer ShellBiscuitJoiningCombJointsFinishStartYes?Measure and mark pine planks to sizeCheck two times that the measurements are correct using atape measure and tri square. Are they correct?Use circular saw to cut the pine planks downCheck measurements of both thepine and the width that the blade will cut each time,using a tape measure. Be careful when using the saw to not put handsor have loose clothing go into the mechanisms. Are themeasurements correct?Mark out the positions on the marrying sections ofthe pine using a pencil and, rule and tri square and check their positionis correct. Are they correct?Biscuit joint the marked out slotsBe sure that thebiscuit jointer in lined up correctlywith your markings before cutting. Check that themarrying pine joins together correctly before moving on. Make suresaw dust goes into a container and not into other people’s eyes. Weargoggles and potentially an apron to prevent loose clothingcatching in biscuit joiner. Do they jointogether correctly?Mark out the biscuit joints slots on the planksYes?Yes?Join pine with biscuitsApply wood glue evenly across both edges ofthe planks to be joined. Fill in the slots with some of the woodglue and insert the biscuits. Join both halves together and then placebetween 2 or more sash clamps, making sure that the planks are level with each other andnot bent by placing a known flat object across the join to see if it raises. Put some MDFstoppers where the clamp would touch the pine to prevent any impressionsand damage occurring. Clean any excess glue off using adamp cloth. Have you done this?Yes?NO?NO?NO?NO?NO?Yes?Join shell components togetherYes?StartMeasure and mark joined pine planks to sizeCheck two times that the measurements are correct using atape measure and tri square. Are they correct?Use circular saw to cut the pine planks downCheck measurements of bothusing a metal rule the pine and the width thatthe blade will cut each time, using a tape measure. Be carefulwhen using the saw to not put hands or have loose clothinggo into the mechanisms. Are themeasurements correct?Make sure that the lines are at right angles using atri square. Check that the markings match up with the pine to bejoined. Are they at right angles and match up?Cut out comb jointsUse a coping saw to cut thevertical lines. Finish with either filing andrasping or use a chisel. Be careful not to change the jointfrom the markings and that components still fit together snugly. Becareful if using a chisel not to get hands in the way. Dothey still fit snugly without beingdeformed?Mark out comb jointsYes?Yes?Yes?Apply wood glue evenly across thesurfaces to be joined. Fit the components together andthen put 2 sash clamps across each joint. Be sure that the shell issquare in the clamps using a tri square. Clean up any excess woodglue using a damp cloth to prevent surface damage tothe pine. Have you done this?Round and smooth edges and cornersUse a half round wood file tomake a slight chamfer on all the edges andcorners to prevent the user from accidentally injurythemselves upon contact. Finish this off by using fine grained sandpaper lightly over the affected areas. Make sure that the shell does not lookdeformed (tri square) after and therefore that the edges andcorners have been rounded and smoothed equally. Arethey rounded enough/ not too muchFinishNO?NO?NO?NO?Yes?Yes?NO?NO?
    • Manufacturing Plan: Main Body - Outer ShellFinishingStartYes?Check dimensionsCheck two times that the measurements are correct using atape measure and tri square. Are they correct?Clean up any excess materialMake sure there is no dried excess glue visuallyspottable. Carefully remove any using the edge of something and/ or ascribe. Have you done this?If not, use a wood file and some fine grain sand paper.Be sure not to over do this stage to keep the shell from lookingdistorted. Are the joints flush?VarnishCheck two times that the measurements are correctusing a tape measure and tri square. Lightly varnish/ bees wax the shellso that it is protected. Are the measurements correct?Check that all the joints are flushYes?Yes?NO?NO?NO?NO?FinishYes?CompartmentSlotFinishYes?StartYes?Mark out area to be routedMark out the shell bottom piece. Check two timesthat the measurements are correct using a tape measure and trisquare and a sharp pencil. Are they correct?Set up the routerSet the depth for all the way throughinitially and check with a metal rule. Make sure that therouting bit is the right dimensions and shape for the sut. Is thebit correct and the marked out area correct?Route out the middle of thebottom section. Be careful to stay within themarked lines. Be careful to not have loose clothing in the wayand to wear goggles. Keep hand away from cutting area. Hasthe router gone all the way through thematerial?2nd Level routingRepeat the previous step , but this time make therouting area 5mm wider on each edge and only set the router to go tohalf the depth.Route throughYes?Yes?NO?NO?NO?NO?Check all measurements with a tapemeasure and try square. If not correct use a chiseland mallet to carefully remove any or material. Once done, make surethat the flat sections are smooth using various gradesof sand paperNO?
    • Manufacturing Plan: Drop Down CompartmentsVeneeringCombJointsJoin components togetherYes?Apply wood glue evenly across thesurfaces to be joined. Fit the components together andthen put 2 sash clamps across each joint. Be sure that the shell issquare in the clamps using a tri square. Clean up any excess woodglue using a damp cloth to prevent surface damage tothe pine. Have you done this?Round and smooth edges and cornersUse a halfround wood file to make aslight chamfer on all the edges and cornersto prevent the user from accidentally injury themselvesupon contact. Finish this off by using fine grained sand paper lightlyover the affected areas. Make sure that the shell does not lookdeformed (tri square) after and therefore that theedges and corners have been roundedand smoothed equallyFinishYes?Yes?NO?NO?StartYes?Measure and mark joined pine to sizeCheck two times that the measurements are correct using atape measure and tri square. Are the measurements correct?Use band saw to cut the pine planks down toCheck measurements of both thepine and the width that the blade will cut each time,using a tape measure. Be careful when using the saw to not put handsor have loose clothing go into the mechanisms. Are themeasurements correct?NO?NO?Make sure that the lines are at right angles using atri square. Check that the markings match up with the pine to bejoined. Are they at right angles and match up?Cut out comb jointsUse a coping saw to cut thevertical lines. Finish with either filing andrasping or use a chisel. Be careful not to change the jointfrom the markings and that components still fit together snugly. Becareful if using a chisel not to get hands in the way. o theystill fit snugly without being deformed?Mark out comb jointsYes?Yes?NO?NO?Square off the endsUse a flat file and possibly a rasp to make surethat the pine is square at both end. Check that you do not goover the marked lines and that you take measurements so that it is the correctsize. Also, use a tri square to confirm this. Are themeasurements still correct?NO?FinishStartYes?Measure the width and sizes of the exterior of the compartmentsCheck two times that the measurements are correct using ametal rule and tri square. Are they correct?Mark out birch plyMark out these dimensions onto theply, but makethe top and bottom parts 2mm longeron each end for the join later on. Check these measurements multipletimes using a metal rule and tri square. Are themeasurements correct?Checkmeasurements of bothusing a metal rule the pine and thewidth that the blade will cut each time, using a tapemeasure. Be careful when using the saw to not put hands or haveloose clothing go into the mechanisms. Make sure theends do not ... Are the measurementscorrect?Veneer pineApply wood glue evenly across thesurfaces to be joined. Fit the components together andthen put 2 sash clamps across each joint. Be sure that the shell is squarein the clamps using a tri square. Clean up any excess wood glue using adamp cloth to prevent surface damage to the pine.Have you done this?Use circular saw to cut the birch ply down toYes?Yes?FinishingMake sure that the edges are flush by lightly using a flat wood file. Be careful not to distortthe shape or go to hard as to ... the edges.Yes?NO?NO?NO?NO?NO?Yes?
    • Manufacturing Plan: Drop Down CompartmentsVeneeringRoutingHousingJointsFinishStartYes?Measure the width and sizes of the exterior of the compartmentsCheck two times that the measurements are correct using ametal rule and tri square. Are they correct?Mark out birch plyMark out these dimensions onto theply, but makethe top and bottom parts 2mm longeron each end for the join later on. Check these measurements multipletimes using a metal rule and tri square. Are themeasurements correct?Checkmeasurements of bothusing a metal rule the pine and thewidth that the blade will cut each time, using a tapemeasure. Be careful when using the saw to not put hands or haveloose clothing go into the mechanisms. Make sure theends do not ... Are the measurementscorrect?Veneer pineApply wood glue evenly across thesurfaces to be joined. Fit the components together andthen put 2 sash clamps across each joint. Be sure that the shell is squarein the clamps using a tri square. Clean up any excess wood glue using adamp cloth to prevent surface damage to the pine.Have you done this?Use circular saw to cut the birch ply down toYes?Yes?FinishingMake sure that the edges are flush by lightly using a flat wood file. Be careful not to distortthe shape or go to hard as to ... the edges.Yes?NO?NO?NO?NO?NO?Yes?FinishYes?StartYes?Measure and mark the cutting areaOn both side pieces of the compartment, markout a 7mm wide channel for the shelves to fit into. Do not go allthe way to the end of the end nearest to the front. Is itcentral and measured correctly?Set up the routerSet the depth for 5mm and check with ametal rule. Make sure that the routing bit is the rightdimensions and shape for the cut. Is the bit correct and themarked out area correct?NO?NO?RouteRoute out the channel. Check allmeasurements with a tape measure and trysquare. If not correct use a chisel and mallet to carefullyremove any or material. Once done, make sure that the flatsections are smooth using various grades ofsand paperNO?Yes?
    • Manufacturing Plan: Drop Down CompartmentsCompartmentBackCompartmentShelvesFinishStartYes?Mark cable holesUsing a large tri square, a pencil and a metalrule, mark where the centre point of the holes will be onto thecompartment back piece. Are they in line with each otherand in the right place?Centre punchWhere the holes are to be drilled, centre punch the centrepoint to prevent the drill from slipping. Is it central?clamp down the back piece in placewith a couple of G-clamps and some scrap wood (toprevent damage). Make sure the hole saw bit is secured in thechuck. Make sure googles are worn and all loose items are out ofthe way. Drill out the holes. Has the hole saw goneall he way through the material?Check measurementsCheck all measurements using a rule and tri square and check thediammeter of the holes with a venier calliperHole sawYes?Yes?FinishingYes?NO?NO?NO?NO?Yes?StartYes?Measure and mark pine planks to sizeCheck two times that the measurements are correct using atape measure and tri square. Are they correct?Use circular saw to cut the pine planks downCheck measurements of both thepine and the width that the blade will cut each time,using a tape measure. Be careful when using the saw to not put handsor have loose clothing go into the mechanisms. Are themeasurements correct?Yes?NO?NO?Finish
    • Manufacturing Plan: Speakers/Side UnitsFormAcrylicCreateJigDowel holesYes?Use a pillar drill to cut at least 4 holes of 6mmdiammeter in both halves of the chipboard/MDF. Make surethese are not in the way of the edges or distorting the shape. Make sureall loose items are tied back and goggles and the guard areon.DowelCut at least 4 pieces of 7mm dowel to 540mm using a benchhook and tennon saw. Make sure bench hook is secure in the vice and thathands to not get caught by tenon saw.FinishYes?Yes?NO?NO?StartYes?CADUse 2D design to create a template of the jig. Make sure tocheck measurements and that they are in the right units.Laser cutterExport the 2D design template to thelaser cutter. Place any acrylic that is big enough ontothe ... Run the program. Make sure that machine has been calibratedand that the cooling system is on. Make sure the lidis closed.NO?NO?Use a band saw to cut the chipboard/MDF markings.Be careful not to put hands in the way of the blade, loose clothing andhair are tied back and that goggles are worn.Finish jig sidesRe-stick the template onto the chipboard/MDF. Use a wood file to get the chipboard/MDF to the correctsize. Make sure the edges coming into contact with theacrylic are smooth and free from dirtCut chipboard/MDFYes?Yes?NO?NO?Mark out chipboard/MDFUse double sided tape to tape two pieces ofchipboard/MDF together to create 2 sides of jig. Use double sidedtape and stick the templates onto chipboard/MDF. Use a sharp pencil toaccurately draw around the templateNO?FinishStartYes?Setting upPlace thehalf of the jig with theconcave curved side into a vice. This is tomake the forming easier. Plug a heat gun into a nearbyplug, but keep the cable out of the way to prevent melting theinsulating sleeve by mistake and causing shock orfire. Have the other half of thejig handy nearbyCADUse 2D design to mark out the acrylic of both speakerunits to the exact size. Make sure to check measurements and thatthey are in the right units.Export the 2D design template to thelaser cutter. Place 4mm white acrylic that is bigenough onto the ... Run the program. Make sure that machine hasbeen calibrated and that the cooling system is on.Make sure the lid is closed.Form AcrylicPlace one strip of thelaser cut acrylic across the half of thejig in the vice. Switch on the heat gun and heat up theacrylic evenly until it starts to become very flexible. Be sure not to holdthe heat gun in one spot to prevent bubbles or burning (and hands!)from occurring.Quickly force the other half of the jig into the acrylic. Use a reasonable weightto keep the pressure on the to of the jig whilst the acryliccools. Be wary not to cause cracks by puttingthe jig together squarely.Laser cutterYes?Yes?Remove acrylicOnce cool remove acrylic from jig. Use a rule and use visual judgments tocheck that the acrylic has not warped, webbed or distorted in shape.Yes?NO?NO?NO?NO?NO?Yes?Finish jigSeparate the two piecesof chipboard/MDF/ Apply some woodglue to the holes in the jig. Place the end of a dowel intothe hole and lightly tap in firmly with a wooden mallet. Do this for allthe holes and then do the same with the other side of thechipboard/MDF. Make sure that the jig stays squareby using tri squares and a metal rule (tocheck measurementsYes?NO?
    • Manufacturing Plan: Speakers/Side UnitsWireSpeakersCreateInternalFrameSide pieceYes?There should be a small section cut out of the sidepiece during the laser cutting. This is for the speaker jack leads to gothrough into the product main body. Check that the relevant cablewill fit through easilyUnit mountAlso during the laser cutting 4 small keyholeshaped holes should be cut out. This is for the speaker/shelfunits to hook onto the main body securely without falling off. Check thatthe screws will fit through the larger hole and not through thesmall hole.FinishYes?Yes?NO?NO?StartYes?CADIf the jig template does not fit snugly with thecurvature of the acrylic, use 2D design to create anothertemplate based on the new dimensions to create the speakermount and back piece and sideLaser cutterExport the 2D designtemplate to the laser cutter. Place 4mm (forside) and 2mm (for rest) acrylic that is big enough onto the ...Run the program. Make sure that machine has been calibratedand that the cooling system is on. Make surethe lid is closed.NO?NO?Cut some off cut pine to 15mmx10mmx70mm using a tenon saw and benchhook. Make sure bench hook is secure in the vice and that handsto not get caught by tenon saw. Use the back piece as a template to mark thepine to the correct curvature. Use a jig saw to create the curvature on thepine pieces. Stick into place on the main acrylic using araldite.Be careful not to inhale or touch the aralditemixtureCheck measurementsCheck that the back piece slots in so that it isflush with the edges of the main acrylic. It should be removablefor future maintenance. Make sure speaker mount fitscorrectly.Internal mount piecesYes?Yes?NO?NO?Check measurementsCheck visually that the pieces all fit into placeNO?FinishStartYes?Speaker mountCheck that the hole for the bell of the speaker and its wireswill fit through the laser cut hole in the speaker mount.Speaker mount holesUsing a pillardrill and hand vice drill 4 2mmholes through the mount piece where thespeaker mounting holes are positioned. Use plenty of lubricantto prevent the acrylic from melting and distorting.Make sure all loose items are tied back and gogglesand the guard are on.Use 4 2mm screws to fix the speaker to themount through the previously cut pilot holes using a handscrew driver. Be careful not to screw it down too hard so thatthe acrylic does not crackSolderSolder the relevant wires in place, thatconnect the speaker to the jack lead. Make sure that the join isas neat as possible to ensure that the connection is strong and won’t fall off. Becareful not to inhale the lead solder fumes or touch the hot endof the soldering iron.Fix speaker to mountYes?Yes?Fix mount in placeUse some Tensol-12 in a syringe. Withthe mount in place, lightly ,squeeze the syringe to causecapillary action on the mount internal curvature of the main acrylic.Make sure it is secure. It is not a big problem if it is not perfectlysquare, but try to get it as square as possible. Do notinhale or touch the Tensol-12Yes?NO?NO?NO?NO?NO?Yes?
    • Manufacturing Plan: Wall BracketFinishingMIGWeldingSet up the welding equipmentYes?Use right angled magnets to secure a tube to a strip.Make sure the MIG machine is set up to the correct temperature,feed rate and that the argon is turned on. When welding be carefulnot to cause “pigeon droppings.”MIG weldConnectthe crocodile clip to thestrip to create a connection. Feed aboutan inch of wire out. Make sure the equipment is on.Carefully touch the wire to the area to be welded. Move the wirearound the channel to create the weld. Repeat for all tubing. Makesure to wear the leathers and a MIG visor and gloves.Make sure that the tubing is still 90oafter the weld using a trisquareFinishYes?Yes?NO?NO?StartYes?Mark out mild steelUse a tape measure, tri square and scribe to measure the mildsteel strips and tubing to sizeCut the mild steel to sizeUse a band saw to cut the mild steel stripsand tubing to size. Make sure that you cut just outsidemarked lines. Keep loose clothing and hair and hands awayfrom the blade and moving parts and weargogglesNO?NO?Make sure the strips are the correct length by using atape measure, tri square and a flat metal file. Clean up the area forthe weldMark and drill mounting holesMark6 holes per strip for thebracket to be mounted to the wall. Use ascribe and centre punch to prepare the strip for drilling.Drill all the way through using a 3mm bit. Use a countersink bit to make thewall screws flush with the bracket. Clean up the edges using a half roundand need file. Be careful not to get hands in the way.Make sure goggles are worn and allloose items are tiedbackPrepare strip for weldingYes?Yes?NO?NO?Prepare for tubing for weldingFile off the ends of the mildsteel tubing with a flat metal file to thecorrect length (using a tape measure and tri square). Then use ahalf round metal file to chamfer one end to create a channel for the weld toform. Clean up the end using coarse grained emery cloth to finegrained. This creates a clean surface for theweldNO?FinishStartYes?GrindingCarefully grind down the welds where there isan excess of...Wear a MIG visor and leathers to protect yourself from theresultant sparksFilingUse a round needle file to make the weld even neaterUse various grades of emery cloth to clean upthe entire structure. This should remove any oxygenatedparts near the welds. It should also prepare the surface for afurther finishCheck measurementsCheck all of the measurements, using a tape measure and tri square.Make sure all the tubing is at a 90o.Clean upYes?Yes?FinishingLay the structure on somenewspaper in a well ventilated area. wear anapron, googles and a face mask to prevent inhalation ofsolvents. Spray the structure with black spray paint (car paint). Leave to dryand then do the other side. Do this 2 or 3 times to create aneven and smooth finish that will extend thelife of the structureYes?NO?NO?NO?NO?NO?Yes?
    • Manufacturing Plan: Drop Down MechanismPulleyMechanismUnitShellJoin components togetherYes?Apply wood glue evenly across the surfaces tobe joined. Fit the components together and then put 2 sashclamps across each joint. Be sure that the shell is square in the clamps usinga tri square. Clean up any excess wood glue using a damp clothto prevent surface damage to the pineRound and smooth edges and cornersUse a halfround wood file to make aslight chamfer on all the edges and cornersto prevent the user from accidentally injury themselvesupon contact. Finish this off by using fine grained sand paper lightlyover the affected areas. Make sure that the shell does not lookdeformed (tri square) after and therefore that theedges and corners have been roundedand smoothed equallyFinishYes?Yes?NO?NO?StartYes?Measure and mark joined pine to sizeCheck two times that the measurements are correct using atape measure and tri squareUse band saw to cut the pine planks down toCheck measurements of both the pine and thewidth that the blade will cut each time, using a tape measure.Be careful when using the saw to not put hands or have looseclothing go into the mechanismsNO?NO?Make sure that the lines are at right angles using atri square. Check that the markings match up with the pine to bejoined.Cut out comb jointsUse a coping saw to cut thevertical lines. Finish with either filing andrasping or use a chisel. Be careful not to change the joint fromthe markings and that components still fit together snugly.Be careful if using a chisel not to get hands inthe wayMark out comb jointsYes?Yes?NO?NO?Square off the endsUse a flat file and possibly a rasp to make sure that thepine is square at both end. Check that you do not go over the markedlines and that you take measurements so that it is the correct size.Also, use a tri square to confirm this.NO?FinishStartYes?Measure the width and sizes of the exterior of the compartmentsCheck two times that the measurements are correct using ametal rule and tri squareMark out birch plyMark out these dimensions onto the ply, butmakethe top and bottom parts 2mm longer on each end forthe join later on. Check these measurements multiple timesusing a metal rule and tri squareCheck measurements of both usinga metal rule the pine and the width that the bladewill cut each time, using a tape measure. Be careful when using thesaw to not put hands or have loose clothing go into themechanisms. Make sure the ends do notVeneer pineMake sure both surfaces to be joinedare free from dirt. Apply wood Glue evenly across bothsurfaces. Apply ply to the correct sides of the pine and then use a G-clamp across both sides. Make sure you use some scrap MDF to preventimpressions and also that the excess glue is cleaned upwith a damp clothUse circular saw to cut the birch ply down toYes?Yes?FinishingMake sure that the edges are flush by lightly using a flat woo file. Be careful not to distortthe shape or go to hard as to ... the edges.Yes?NO?NO?NO?NO?NO?Yes?
    • Manufacturing Plan: AssemblyFixingWiringJoin components togetherYes?Apply wood glue evenly across the surfaces tobe joined. Fit the components together and then put 2 sashclamps across each joint. Be sure that the shell is square in the clamps usinga tri square. Clean up any excess wood glue using a damp clothto prevent surface damage to the pineRound and smooth edges and cornersUse a halfround wood file to make aslight chamfer on all the edges and cornersto prevent the user from accidentally injury themselvesupon contact. Finish this off by using fine grained sand paper lightlyover the affected areas. Make sure that the shell does not lookdeformed (tri square) after and therefore that theedges and corners have been roundedand smoothed equallyFinishYes?Yes?NO?NO?StartYes?Measure and mark joined pine to sizeCheck two times that the measurements are correct using atape measure and tri squareUse band saw to cut the pine planks down toCheck measurements of both the pine and thewidth that the blade will cut each time, using a tape measure.Be careful when using the saw to not put hands or have looseclothing go into the mechanismsNO?NO?Make sure that the lines are at right angles using atri square. Check that the markings match up with the pine to bejoined.Cut out comb jointsUse a coping saw to cut thevertical lines. Finish with either filing andrasping or use a chisel. Be careful not to change the joint fromthe markings and that components still fit together snugly.Be careful if using a chisel not to get hands inthe wayMark out comb jointsYes?Yes?NO?NO?Square off the endsUse a flat file and possibly a rasp to make sure that thepine is square at both end. Check that you do not go over the markedlines and that you take measurements so that it is the correct size.Also, use a tri square to confirm this.NO?FinishStartYes?Measure the width and sizes of the exterior of the compartmentsCheck two times that the measurements are correct using ametal rule and tri squareMark out birch plyMark out these dimensions onto the ply, butmakethe top and bottom parts 2mm longer on each end forthe join later on. Check these measurements multiple timesusing a metal rule and tri squareCheck measurements of both usinga metal rule the pine and the width that the bladewill cut each time, using a tape measure. Be careful when using thesaw to not put hands or have loose clothing go into themechanisms. Make sure the ends do notVeneer pineMake sure both surfaces to be joinedare free from dirt. Apply wood Glue evenly across bothsurfaces. Apply ply to the correct sides of the pine and then use a G-clamp across both sides. Make sure you use some scrap MDF to preventimpressions and also that the excess glue is cleaned upwith a damp clothUse circular saw to cut the birch ply down toYes?Yes?FinishingMake sure that the edges are flush by lightly using a flat woo file. Be careful not to distortthe shape or go to hard as to ... the edges.Yes?NO?NO?NO?NO?NO?Yes?
    • Date Task to be Completed (Predicted) Date Task Actually Completed (Actual)Exam Period Holiday PeriodGaant ChartWeeks Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9Tasks dates 7/1/13 14/1/13 21/1/13 28/1/13 4/2/13 11/2/13 18/2/13 25/2/13 1/3/13Mounting Bracket PredictedForming ActualMounting Bracket PredictedDrilling ActualBracket Pin PredictedMilling ActualBracket Pin PredictedDrilling and Finishing ActualLocking Pin PredictedForming ActualMain Body PredictedMarking Comb Joints ActualMain Body PredictedCutting Comb Joints ActualMain Body PredictedAdjusting Joints ActualMain Body PredictedCutting Compartment Slot ActualMain Body PredictedAdjusting Compartment Slot Actual
    • Date Task to be Completed (Predicted) Date Task Actually Completed (Actual)Exam Period Holiday PeriodGaant ChartWeeks Week 10 Week 11 Week 12 Week 13 Week 14 Week 15 Week 16 Week 17 Week 18Tasks dates 1/3/13 8/3/13 15/3/13 22/3/13 29/3/13 6/4/13 13/4/13 20/4/13 27/4/13Main Body PredictedAssembly/Finishing ActualSpeakers/Side Units PredictedCreate Frames ActualAmplifier PredictedWiring ActualAmplifier PredictedLaser Cutter ActualSpeakers PredictedMounting ActualWiring PredictedAll Components ActualDrop Down Compartment PredictedComb Joints ActualDrop Down Compartment PredictedAssembly/Finishing ActualSpeakers PredictedHIPS ActualModifications PredictedModifications Actual
    • Date Task to be Completed (Predicted) Date Task Actually Completed (Actual)Exam Period Holiday PeriodGaant ChartWeeks Week 19 Week 20Tasks dates 4/5/13 11/5/13Testing and Evaluation PredictedTesting and Evaluation ActualFinishingFinishing ActualPredictedActualPredictedActualPredictedActualPredictedActualPredictedActualPredictedActualPredictedActualPredictedActual
    • Cutting List- FinalStudent Olli DerhamHouse Sutton ALL IN MMForm U6thAmount Material Description Length Width Thickness Letter2 MDF Sides 636 400 18 A1 MDF Top (Front) 850 100 18 B1 MDF Top (Back) 850 300 18 C1 MDF Screen Mount 832 618 18 D1 MDF Comp. Back 712 252 18 E1 MDF Bottom 850 400 18 F2 MDF Comp. Sides 270 266 6 G1 MDF Comp. Top 712 280 6 H1 MDF Comp. Bottom 722 290 6 ITotal £80
    • ABDCA= Grain DirectionECutting Plan - MDF Oak Veneer 18mm (2440x1220)F
    • 305mm77mmrouted groove18wide, 9deepNeed slot routed/ cut for both Apieces. Ignore the cut out bit at thetopA 280mm712mm90mm (just before routed edge)F(top)F(bottom)77mm290mm722mmrouted inset, 9mm deep, 5mm wide
    • E5mm123mm 175mmG130mm265mm5mmAll three sets of grooves to berouted to 3mm deep and 6mm wide
    • Cutting Plan - MDF Oak Veneer 6mm (2440x1220)IHG G= Grain Direction
    • SafetymeasuresEye ProtectionSkin ProtectionRespiratoryprotectionGeneralawarenessEvaluation of dangerlevels of situation,GlovesGogglesMask,increased ventilationWorking withbladesElevated levelof alertnessMarkingSawingSandingDovetailingBiscuit JoiningSafety PrecautionsTasks What it will effectMake sure equipment is cleanPersonal Safety/mistake preventionOther’s SafetyTest/practice withequipment
    • SafetymeasuresEye ProtectionSkin ProtectionRespiratoryprotectionGeneralawarenessEvaluation of dangerlevels of situation,GlovesGogglesMask,increasedWorking withbladesElevated levelof alertnessRoutingGluingPolishingOtherSafety PrecautionsTasks What it will effectVarnish/StainingMake sure equipment is cleanPersonal Safety/mistake preventionOther’s SafetyTest/practice withequipmentThermal Forming
    • Quality Control TextSafety Control TextManufacturing Log
    • Manufacturing: Mounting BracketOn a sheet of aluminium, mark out a rectangle150mmx80mm using an engineering square and a scribe.Use a fine liner to help define the scribe markUse a hack saw to cut down the straight edges Use a metal file to smooth the edges to remove thehazard of cutting yourselfCut 4 edges (50mm in height) at 45 degrees to thehorizontalFile off the burr to smooth the edges With 2 centre points marked the quadrants use acentre punch to define the point at which the drill willcutUse a pillar drill to drill 2 M5 holes at the markedpointsPractice using the former to create the 90 degreeangle neededWith the actual bracket now form the 2 triangularareas at 90 degrees to the middle sectionUsing a 50mmx50mm piece of scrap wood, place it inbetween the two sides. This will support the bracketwhilst you mark a point 20 mm from the top pointand centre punch it.With the aluminium still on the block, use the pillardrill to drill through the marked point. Use a straightobject to make sure that both holes are lined upCheck for any deformities and whether there are anydangerous edges
    • Manufacturing: Bracket PinTake a steel rod of 12mm in diammeter of at least 150mmin lengthCheck the diammeter is correct using a set of verniercalipersPlace the rod in the headstock of the lathe and tightenwith a chuck key (remember to remove it after!). Usethe centre drill in the headstock to create a centrereference pointOnce the centre drill has been used the rotatingcentre can be firmly locked into place inside thecentre hole. This reduces wobble and therefore willincrease the accuracy of the lathe workUse the cutting tool in the tool post to start reducingthe diammeter of the rod across a 70mm length. Byreversing the gearingKeep using the venrier calipers to check that thediammeter does not go lower than 6mmTo prevent over heating and to produce a cleaner cutuse coolantOnce the cut end is 6mm in diammeter use the facingtool to cut the rod with a 10mm large end. Face offboth end to create a clean finishUse a 2mm drill bit, with the rod in a hand vice, todrill all the way through the 6mm end about 15mmfrom the endPlace the actuator in the hand vice and use a 6mmdrill bit to widen the hole at the endFile off any burr created during the drilling processusing a flat hand fileThe finished component
    • Manufacturing: Bracket Locking PinManufacturing: Mechanism Load Test 1Make sure that it fits snuggly into the hole drilledearlier. the bend should lock it into place without itsliding off. Make sure to file and round off theedges of the wire to prevent injuryThe finished componentWith a 1.5mm thick length of wire, use aformer to bend it into an s shape with a flatedgeWith the actuator securely fitted with safetygoggles and equipment on clamp a fewweights to the woodBy connecting the wires of the actuator temporarily to anexternal power supply test the up and down movement ofthe actuator. Make sure to look out for mechanical failure(also heard by noise made)Mount the bracket onto a test piece of wood
    • Manufacturing: Main BodyTake on of the larger sheets of the MDF(850mmx400mmx18mm) and check themeasurements with a tape measure. Whilst doing thisalso make sure that it is square by using a large trysquareMeasure 18mm out from the shorteredgesAt this point, use a rule and try squareto draw a line parallel to the edge, thefull length of the sideAt 50mm intervals draw perpendicularlines using a try square. These will becomethe comb joints.Repeat the process of drawing a lineparallel to the short edge of one of thesheets of MDF (650mmx400mmx18mm)Again, using a try square drawperpendicular lines at 50mmintervalsUse the try square on the now marked 2 sheets todraw perpendicular lines from the marked points, todistinguish the edges. Shade in the parts to be cut.Make sure that they are alternate with each other tocreate the comb joints at the endPlace the other MDF sheet(650mmx400mmx18mm) end on withthe marked oneRepeat the process of drawing a parallelline the full length. Mark the perpendicularlines in using a try square. This shouldhelp match the jointsMake sure that they match with each other Finish by shading the parts on the top of thesheets to show the parts to be cutOn the top edge piece, repeat the same process. Theonly difference is that only 2 comb joints will be madeon both sides
    • Position the component so that one edgeoverhangs the work benchUse the band saw to cut the vertical lines accurately,making sure all safety equipment is on and that handsare not in the vicinity of the moving blade. Then use acoping saw to cut out the middle of each joint,making sure not to go over the marked linesUse a flat file to make the jointssquareUse a needle file to modify the jointsso that each component will joinsnugglyBefore cutting the next component, checkthat the markings still correspond to thecut jointsUse a large try square to mark a line20mm from one edge and 90mm from theotherRepeat this again, but this timemark a line 65mm from both edgesCheck that the lines are perpendicular The linesOn the inside corners of the newly drawnrectangle, centre punch a reasonabledistance from the cornerUse a hand drill and a 8mm bit to drill ahole at each cornerA holeManufacturing: Main Body
    • Use several G clamps and scrap wood toclamp the component firmly into position onthe deskUse a jig saw to cut along the lines.This is where the holes come in (togive an entry point or the blade)Keep moving the component andclamping it down until the middlecomes outUse the bottom piece of the compartmentcomponent to mark where adjustmentsneed to be made for it to fit through thecentreWith a Fein tool and a straight piece ofscrap wood clamped along the lines, raspthe edges so that a square rectangle ismade that the compartment will fit throughCut 4 strips of pine,50mmx20mmx700mm using atenon saw and bench hookUse the elephant sander with great care to make surethat the ends are square and that all of the strips arethe same lengthMeasure 75mm from the edges of thebottom component and mark wherethe strips will goMake sure that this mark is square Mark 3 holes (at 150mm, 350mm and550mm) using a try square, rule andpencil. centre punch where they are to bedrilledUse a hand vice and pillar drill with a 3mm bitto drill a pilot hole at each markApply an even layer of PVA wood glue to the face tobe joined. Do this in a ventilated areaManufacturing: Main Body
    • Stick the strips in position using a G clamp tosecure it firmly whilst the glue driesUse a countersink bit to countersinkthe drilled pilot holesScrew 3 60mm pozidrive wood screwsinto the pilot holes. Make sure that thecountersink head is flush with thesurfaceThe clamps can be removed once the gluehas curedUse sash clamps and PVA wood glue to nowjoin all of the main body components. Use atry square to make sure that all parts aresquare. Make sure that everything is secureManufacturing: Main Body
    • Manufacturing: Drop Down CompartmentUsing a pencil and rule mark 3 6mm lines at7mm, 14mm and 21mmJoin up the lines using a try square forsquarenessMatch up the sides with the bottomcomponent, much in the same way asthe main bodyShade in the parts to be cutUse a coping saw to cut the joints out. Makesure it is clamped firmlyUse a flat file to make the jointssquareUse a band saw where possible to get the joints cutthe most accurately. Be weary of hand positioning andthat goggles are worn and loose articles are awayfrom the moving partsMake sure that the components fit snugglyLightly sand the surfaces to remove pencillines and to provide a clean joining surfaceUsing a pair of pliers to position the tacksalong the tall edge of the side piecesUsing PVA wood glue evenly coat the edges tobe joined of all the componentsMake sure that everything is lined up during theglueing process using a try square. Then finish off thetacks by hammering them through the outer edge andinto the end of the joining component
    • Use a bin liner to line the bottom component of themain body. This will prevent any PVA glue sticking toits surface as it will not join to plastic.Place the glued compartmentcomponents in the hole. This is thehole it will be moving through so it willhelp to shape it properlyOnce dry the compartment can beremovedOn the back panel, mark 145mm fromboth inside edges (along) and then 20mmup. This point should then be centrepunchedUsing a drill with a sturdy hand grip, put ahole saw bit of 36mm diammeterWith the component clamped down firmly,drill out the marked points with the drill.Wear goggles and keep all loose items andlimbs away from the moving componentsUse a large ruler to mark a line where theoverhang isUse the same ruler to draw 2 diagonallines from the new rectangle drawn.This will find the centre point (wherethey cross)What it will look like Measure out the dimensions of the mountingbracketUse a large try square to drawn a rectangleabout the centre point using the measureddimensionsUse a rule to check that the dimensions arecorrectManufacturing: Drop Down Compartment
    • Place the bracket in the drawn rectangle (onthe centre)Use a centre punch to mark exactlywhere the holes are going to beDrill out the holes using a 4mm drillbit. Clamp the wood down firmly toprevent slippageUse M4 machine screws and a nut to boltdown the bracket onto the top piece. Whendoing so use 2 M4 penny washers both sidesof the wood in order to spread the loadThe top piece can now be attached to therest of the compartment using the tackingand glueing process used beforeAny gaps can be adjusted afterdryingMake sure that the compartment can still takethe size and weight of peripheralsMeasure the distance of the holesdrilled earlier from the edge of thecompartmentMeasure this same distance out on the topcomponentUse a try square to mark 2 lines (each side)of 15mm and 20mm apartMake sure that the rectangles drawn are inline with the holes drilled earlierUse a tenon saw to cut the straight lines.Make sure the compartment is securelyclamped downManufacturing: Drop Down Compartment
    • Use a needle file to make the resulting groovesquareThe groove for the wiresManufacturing: Drop Down Compartment
    • Manufacturing: JIGUsing a piece of MDF, Sized larger than 636mmx318mm,drill a small pilot hole mid way. Screw a piece of scrap stripwood with two hole spaced 318mm apart at one end intothis hole. With the other hole push a pencil into place.Making sure that the pencil does not move draw a semicircle using the strip as a guide.After checking the size with a rule, draw a vertical lineusing a tri square and pencil to create the outer flatedge of the speaker shell. Be sure that the speakerswill have enough room to fit within the width createdUse double sided tape to secure a second piece ofMDF to the marked piece. This will make the cuttingand shaping process simpler and also create identicalpiecesMake sure the two pieces are secureMake sure the dimensions of the markingsare correct with a ruler and try squareUse the circular saw to cut cleanly slightlyoutside of the line marked verticallypreviouslyTrim the bottom edge to make a square flatsurface for the jig to sit onUse the band saw along the remaining arcs of thesemi circle. These will be the curved parts of thespeaker shellCheck that both pieces of MDF have been cut thesame and that the dimensions are still correct,particularly the long side as the edges will have tomarry up with the product’s main unitUse a piece of paper and a pencil to trace a curve.This will be for the edges of the arcs that are on theshort side to make them more rounded as the acrylicwill not form such a sharp angle. By doing this thecurves on both side will be identicalUsing a half round file, file down the edges of the arcsto the markings. Take care not to be uneven. Theresulting curves should be smooth and identical onboth sidesUse a tri square to mark a centre line. Using this lineas a guide make sure that both sides are identical.After this, separate both pieces of MDF
    • Use some masking tape to set the depth ofthe hand drill to the thickness of the MDFUse a 4mm drill bit and go to the set depth. Thenscrew some M5 countersink screws into the pilotholes. Make sure the 5mmx5mm pine is fitted solidlyMake sure pine separators are in the correctplacesRepeat the previous processes for the other MDFsheet, making sure that the MDF sheets are in line atthe endManufacturing: JIGMake sure you use a nail that will go through thethickness of the MDF and also a suitable depththrough the pineUse a hammer to hammer 2 nails into place (per endof the 5mmx5mm pine). Be sure to leave a suitablegap between each nail for a screw to be placed lateron. Mind where fingers are placedMake sure that the Pine separators are square with theMDF using a tri square and possibly a spirit level.Then make sure that the pine will not interfere withthe forming process, then that the nails are correctlyplacedUse a hammer and centre punch to mark where thepilot hole will be drilled (between each pair of nails)With some 5mmx5mm pine, use a tape measure tomeasure out 4 396mm lengths. These will be theseparators of the two MDF sheet componentsUse a tri square and a pencil/scriber to mark at least 2 sideof the 5mmx5mm pine to help make sure that they are cutsquarely. These can be cut either using a tenon saw andbench hook or the circular saw (making sure that a 3mmgap is accounted for between each cut)Place one of the cut length of 5mmx5mm pine in avice and move it so that it is flush with the MDF whensat on the work spaceApply some PVA wood glue evenly across thesurface of the 5mmx5mm pine
    • Manufacturing: AmplifierCheck that all of the components are in thekitSet up the soldering equipment on a work bench. Youshould have a soldering iron, a damp sponge, somesoldering wire and a work areaMake sure that it is actually on the desk andthat the surrounding area is clearUse a pair of needle pliers to bend the ends of thefirst resistor at 90 degrees, so that the end fit snugglyin the specified slotsPlace the resistor in the designated space Use the soldering iron to first heat up the point atwhich the joint will be made. Next carefully feed thesolder into place until a runny drop covers both thehole and the wireTrim the excess wire using a pair of wirecuttersRepeat this for all of the other components. With thecapacitors, however, it is vital that they are connectedthe right way around to prevent it from blowing upand spewing molten metalTidy up all of the joints to make them neatand reduce risk of catching yourself on theburrIf needed more solder can be applied to improve theconnection where the solder didn’t reach or where adry connection was madeThe finished PCB: Bottom The finished PCB: Top
    • Manufacturing: SpeakersUsing the previously made jig as a guide draw thespeaker housing shape on a sheet of MDF with thespeaker positioned centrallyAs more than one sheet could berequired, use double sided tape tomake identical copies of the shape andalso to prevent slippage on machinesMake sure the sheets are secure Cut out the long sides of the shapes on thecircular saw. Be careful where hands areplaced and that the extraction is onUse the band saw to cut the outline of thecurved edges. Be weary of the positioningof handsAfter following the same shaping methods of thepreviously made jig use a centre punch to mark thecentre of where the speaker hole will be. Then firmlyclamp the shapes down on the pillar drill and use a110mm hole saw to cut the holes outRepeat the process of creating the 8 struts by startingwith a try square to mark lengths of 390mm on a longstrip of pineUse a tenon saw and bench hook tocut these on the outer side of themarked lineCarefully use the elephant sander with aguide to make sure the ends are squareUse a try square and a rule to mark acentre point 40mm from the ends on 2strips. Then mark another point 10mmaboveMake sure that the point correspond on bothstrips using a try squareMake sure that the centre points are at thesame level so that the speakers won’t hang atan angle
    • Centre punch the centre of the marked holes Drill through both holes with a 6mmbit. Use a hand vice to prevent thewood from spinning outUse a 10mm bit to drill the centreholes out. Again use a hand viceUse a needle file to join the holes up. Thiswill be the way in which the speaker hangsfrom the main bodyMake sure that the front and back pieces lie square. Inthe same way as the jig, Use the same method as withthe jig by using two nails per end of the strut to prejoin the pieces (with PVA wood glue in between. Thenfinish it off by screwing them down.Use a damp cloth and a chisel (be carefulnot to put hands in the way) to removethe excess stickiness where the doublesided tape wasIn a suitable container, squirt this amount ofPVA wood glueAdd water to the PVA until it becomesthis consistency.Use a roller to apply this watered down PVAover the front surface of the speakerhousing. This will help seal the MDF so thatit can be painted on without disintegratingUse another suitable tray to put some blackacrylic paint inAgain use a roller so that the paint is appliedeven so there are no visual defectsOnce dry, you may want to apply a few morecoats to measureManufacturing: Speakers
    • Take the amplifier and mark where it will bepositioned on a front piece of the speakerhousingMeasure the dimensions of the amplifier witha ruleSketch out all the measurements to geta visual. Then use 2D design to createan input file for the laser cutter. Thiswill be the front of the amplifierSend the CAD file to the laser cutter. Thiswill cut the design perfectly. Make surethat the ventilation system is on and thatthe lid is down to prevent physical injuryMake sure that the piece fit the amplifier Screw the piece onto the frontusing the nut on the volume knobUse a try square to make the marked linemade for the amplifier position squareMake sure that the rectangle drawn fitsthe amplifierSet up a hand drill with a 3mm bit Drill a hole in the corner of the rectangle Use a scroll saw to cut out the rectangle. Makesure that hands are not in the way of the bladeAdjust the rectangle size using various files. Thenplace the amplifier in the slot. It should be held justby the laser cut piece due to the accuracy of the cutManufacturing: Speakers
    • Make sure that the speaker housing is secure The speakers can now be mountedusing the provided screws. These mayneed to be cut down to the requiredlength using a metal vice and hack sawMark 2 points midway on the struts(on the long side) of the housing.These should be 50mm from the endsCheck that the holes are on the same levelusing a try squareUse a centre punch to create a guide for thedrill bitDrill through these points using a2mm bit to create a pilot holeWith a strip of HIPS placed underneath (to get thecorrect starting height) line up the speakers and use70mm pozidrive screws to firmly attach the speakersto the main body. This will also sort out any warpingthat may have occurred during manufactureAn attached speakerOnce the speakers are attached, firmly clampthe main body to the desk so that there is nomovementMark a line midway on the side panels ofthe main body. Check this using a trysquare and ruleUse a hand drill with an 8mm bit to drill a holeat the centre point. This will be where thewiring can go through to reach the speakersand amplifierWhat happens with the wiresManufacturing: Speakers
    • Unscrew the supplied machine screws fromthe base of the actuatorUse the holes to mark 3 point roughlyon the top - back piece.Use a rule to mark out the dimensionsof the actuator and the actualpositions of the screw holes, using themarked points as a guideCheck that the holes line upCentre punch the marked points With the piece clamped firmly onthe pillar drill, drill out the holeswith a 4mm bitMake sure the holes are in the correctpositionUse a hand drill and a countersink bitto countersink the out side of thepieceGet some 70mm M4 machine screws Mark out 50mm on the screws with a finelinerCut the machine screws down to size with ahack saw and a metal viceUse impact adhesive to stick 2 5mm pieces of MDFtogether (pre cut to the same size as the base of theactuator). Do not get the adhesive near the mouthManufacturing: Mounting Actuator
    • Leave the 2 pieces of MDF for 10 minuteswhilst clamped firmly in a vice to secure themAs before mark out where the holesfor the actuator will be with a rule andtry squareCentre punch the marked holes Use a pillar drill to drill out the holes with a4mm bitBut the actuator onto the dried MDF picecsand mark out where the indent will need tobeUse a mortice machine to cut outthis indentMake sure that the actuator sits flat on thepanelUnderneath - the machine screws should beflush with the surfaceManufacturing: Mounting Actuator
    • Manufacturing: WiringAfter soldering the power lead to some speaker wire,test the direction of the circuit current using a multimeterMark the positive lead using thesoldering iron, taking care to not burnfingersSolder the ends of the speaker cable tothe designated points. Take care tonot burn self or inhale lead fumesOn the opposite end of the wire now markthe positive with the soldering iron and tinthe endsMake sure that both speakers are wiredcorrectlyMake sure that the speakersthemselves (particularly thediaphragm) are not deformedBoth speakers are now wired With the tinned ends of the speakercable, screw them into the correctslots in the terminal block on theamplifierWith the power lead, cut off the end sothat the wires can be stripped and tinnedand permanently fixed into the circuitryDo the same with one end of a jack lead With the white and red wires of the jack lead makesure they are soldered onto the PCB with the labelsIn1 and In2. The label “Black” is where the bare copperwires should be soldered. Take care to not inhale leadfumes or burn selfMake sure that all wires are secured to thePCB of the amplifier
    • Use a pair of vernier calipers to measure theexact dimensions of the switchUse a rule to mark the position wantedfor the switchUse a hand drill and a 8mm bit to drilla hole where the switch position hasbeen markedWith the piece clamped down, use a copingsaw to cut the hole out. Use a needle fileto adjust the size accordinglyStrip the ends of the power lead wire usingwire strippersOnly take about 10 - 15mm off theendCarefully tin the ends of the wiretaking care not to burn self or inhalelead fumesBe careful not to create dry solderIf needed, the length of the wire can beadjustedSecure the power lead to one sideof a terminal blockWith a DPDT switch, wire it using a soldering iron sothat the actuator is connected across the middle pinsand hat 2 more wires are cross connectedThis should allow the actuator to movein both directionsManufacturing: - Switch
    • Make sure that the wiring has not beenaffected when the switch has beensecured. The power lead may now also besoldered to and end of the switchSwitch - Top Switch - SideManufacturing: - SwitchManufacturing: - WiringWith the wires, use cable tacks to securethem in place so that they are not loosewithin the productIt should now be a lot neater Main body with wired speakers andcompartment
    • To get the perfect curvature, the ends may have to beelevated to put maximum force on the ends. This willhave to have a few hours between each section tomake sure the glue is curing. Be careful of positioningso it does not fallClean the contact positions of the speakerswith a damp cloth to remove dustA hoover may also be used to makesure that the contact points are freefrom dirtUsing a cloth tape measure, measurethe length of the sidesUse a circular saw to cut the 2 sheets of HIPSto the measured dimensionsRead the impact adhesive instructions. Do notingest or inhaleApply an even layer ate the contactpoints. Let this go tacky (after 5-10minutes)When tacky join the two surfaces, section bysection, making sure that everything is linedupKeep apply pressure as you join thesurfacesThe bottom side may be tacked for extrastrengthMake sure that the HIPS does not slipduring this processFor added strength, use Evo-Stick Serious Stuff.This will likely be a stronger solution for thejoinManufacturing: HIPS Speaker Casing
    • Cut the applicator end of the sealant at anangle suitable to get into the caps of thespeaker. Be very careful when using theStanley knife not to catch fingersCarefully follow the inside edge with theapplicator to fill all the gaps and also tocreate an even finishUse a scraper to remove any excess. Makesure to wash hands straight after to preventingestionThe speaker casing is nowcompletely finishedManufacturing: HIPS Speaker Casing
    • Manufacturing: Front PanelOn a sheet of Ash veneered MDf, measured to the sizeof the front space of the main body and cut on acircular saw, sand down the edges to give the best fitKeep checking that it fits snuggly onthe strips made at the beginningWith a rule and pencil mark 4 holes (2top and 2 bottom) 215mm from thesidesMark these points 20mm from the edgeAfter centre punching use a hand drill with a2mm bit to drill a pilot hole through the MDFsheet and part way through the woodenbacking strip. Be careful of slippagesFollow this up by using acountersink bit to countersink theholeThis may be done until the screws to be usedsit flush with the surfaceOnce done the pozidrive screws can bechecked for correct lengthThe pozidrive screws can now be screwedin. The front of the product is nowfinished!View from the front View from the back
    • Measure out the dimensions of the edges to beveneered using a rule. Then use the rule as a guide touse a Stanley knife to cut the edging veneer to thespecified dimensions. Be very careful with the bladeBe careful when separating the veneerto not split itBefore ironing on, make sure theveneers are the correct sizeUse an iron to melt the glue backing tosecure the veneer to the MDF surface. Bevery careful not to burn self or burn thewoodThis may take a while as all the visibleedges must be veneeredWhen done the product should looklike solid AshAdjustments can be made by reheating theglueAny size adjustments can be made bycareful trimming with the Stanleyknife. Again be very careful with thebladeUse various grades of sand paper on n oakblock to round and smooth the edgesUse the larger grain to first remove dents Use the medium grain to remove pencil line The fine grain should make the wood smoothManufacturing: Veneering and Finishing
    • Use a force plate to measure the weight ofthe product exactlyManufacturing: WeightUse the screw in feet to adjust the leveling ofthe force plate so that it is perfectly levelPlace the product on the force plateUsing Data Studio record the Weight (inNewtons) on the ticker and also graph it atthe same timeWith a line of best fit the exact weight can bemeasured and then converted into KG bydividing by 9.81
    • Manufacturing: Other ProcessesTest out the iron on veneer to see what temperature isrequired and for how long the iron will need to beapplied. Be very careful not to touch the bottom of theiron, particularly after useMeasure the height of the mountingbolt to see how much it raises upAt each corner of the compartment, stick feltfeet to the height of the bolt. This will raise aflat platform to remove the wobble caused bythe boltsUse a circular saw to cut a sheet of 3mm HIPS tothe dimensions of the inside of thecompartment Be very careful not to place handnear moving parts and to wear safety equipmentRepeat process used for the front panelmounting. 3 holes should be marked(centre and 110 from each end)Measure the position from each side to makesure that it will be fixed on the middle sectionof the bottom panelPilot hole and countersink the holes for aflush finishUse a set of vernier calipers tomeasure the thickness of the multisocket power cableMeasure 84mm up and 1555mm across witha rule and pencil. This will be where the firstscrew will be placed to mount the multisocket. On the same level, 100mm further toMake sure to use a PAT tested multi socket
    • Actuator - Compartmentmovement mechanismSpeakersAmplifierCircuitry Schematic - Drawn using Digi-KeyUsed as a test whenwiring was notfunctioningcorrectly
    • Specification Point Testing and Evaluation Picture Client Response• Performance Requirements:- Should function for around 10 upand down movements a dayThe way in which I tested the Actuator was bytesting the up and down movement on separateoccasions. I did this by turning it on in 10 sets ofup and down phases.What I found was that theactuator when loaded now makes a louder noisethan it did initially without a load. From severaltheories I have put this down to the carbonbrushes in the motor pushing too much againstthe coils in the motor. Despite this it does stillwork and as the movement will only be initiatedfor a short period it should not affect the usertoo much.• Performance Requirements:- All wiring and electrical suppliesmust be PAT testedThe way in which I tested the Actuator was bytesting the up and down movement on separateoccasions. I did this by turning it on in 10 sets ofup and down phases.What I found was that theactuator when loaded now makes a louder noisethan it did initially without a load. From severaltheories I have put this down to the carbonbrushes in the motor pushing too much againstthe coils in the motor. Despite this it does stillwork and as the movement will only be initiatedfor a short period it should not affect the usertoo much.• Function- Must support the weight andnumber of books typically foundon a bookshelf (about 15)- Must not break down after afew uses and also in the processnot produce disturbing noisesThe way in which I tested the Actuator was bytesting the up and down movement on separateoccasions. I did this by turning it on in 10 sets ofup and down phases.What I found was that theactuator when loaded now makes a louder noisethan it did initially without a load. From severaltheories I have put this down to the carbonbrushes in the motor pushing too much againstthe coils in the motor. Despite this it does stillwork and as the movement will only be initiatedfor a short period it should not affect the usertoo much.• Performance Requirements:- Should function for around 10 upand down movements a dayI tested the switch during the testing of theactuator. In doing this I was testing theresponsiveness when used. I found it to be veryresponsive when working, although I did have tore-solder the connections due to 2 being looseand causing the actuator to only move in onedirection. I also used a multimeter to make surethe correct current was going across eachconnection to prevent any future issues with thecircuitry• User Requirements:- Must have a simple method ofoperating any electrical ormechanical systemsI tested the switch during the testing of theactuator. In doing this I was testing theresponsiveness when used. I found it to be veryresponsive when working, although I did have tore-solder the connections due to 2 being looseand causing the actuator to only move in onedirection. I also used a multimeter to make surethe correct current was going across eachconnection to prevent any future issues with thecircuitry• Safety:- All wiring and electrical suppliesmust be PAT testedI tested the switch during the testing of theactuator. In doing this I was testing theresponsiveness when used. I found it to be veryresponsive when working, although I did have tore-solder the connections due to 2 being looseand causing the actuator to only move in onedirection. I also used a multimeter to make surethe correct current was going across eachconnection to prevent any future issues with thecircuitryTesting and Evaluation
    • Specification Point Testing and Evaluation Picture Client Response• User Requirements:- Screen and speaker systems mustbe compatible with differentcomputer operating systemsI have been testing the speakers since I installed them ontothe main body.At first the standard of the sound was onlygood in the Treble and Mid ranges due to there being noBass output. By enclosing the speaker housing with HIPSthe air now vibrates with the speaker, which now creates aBass affect.This makes the speakers sound really clear andhigh quality.The sound is also very loud at maximumvolume. It is more than enough to fill a conference room.To prove this I recorded the magnitude of decibelsproduced when playing a song, starting at low volume andfinishing at maximum volume. I also graphed this data ontotwo graphs for comparison• Performance Requirements:- The structure must incorporate aspeaker systemI have been testing the speakers since I installed them ontothe main body.At first the standard of the sound was onlygood in the Treble and Mid ranges due to there being noBass output. By enclosing the speaker housing with HIPSthe air now vibrates with the speaker, which now creates aBass affect.This makes the speakers sound really clear andhigh quality.The sound is also very loud at maximumvolume. It is more than enough to fill a conference room.To prove this I recorded the magnitude of decibelsproduced when playing a song, starting at low volume andfinishing at maximum volume. I also graphed this data ontotwo graphs for comparison• Function- Be a product that can be used forpresentation purposes.I have been testing the speakers since I installed them ontothe main body.At first the standard of the sound was onlygood in the Treble and Mid ranges due to there being noBass output. By enclosing the speaker housing with HIPSthe air now vibrates with the speaker, which now creates aBass affect.This makes the speakers sound really clear andhigh quality.The sound is also very loud at maximumvolume. It is more than enough to fill a conference room.To prove this I recorded the magnitude of decibelsproduced when playing a song, starting at low volume andfinishing at maximum volume. I also graphed this data ontotwo graphs for comparison• Performance Requirements:- Should function for around 10 upand down movements a dayI tested the moving compartment in a few ways. I loadtested the compartment using everyday peripherals, suchas a laptop and external hard drive.When placed insidethe compartment is very sturdy due to the comb jointsand also the fact that the actuator is directly beneath.When placed on top the top panel slightly warps.Thiscould be due to there being no comb joints and also noreinforcement.The other way I tested the compartment was its positionbefore and after movement. I found that after it hadmoved upwards from its starting position it moves slightlybackwards. I have found this to be a result of the type ofmounting bracket I used and also the natural wobblecaused by the movement of the actuator. I have sincecorrected this by installing guide rails. I also added someheight to the actuator by adding an MDF block under themounting bracket to make the compartment flush withthe main body surface when in the down position• Function- Must support the weight andnumber of books typically foundon a bookshelf (about 15)- Must not break down after afew uses and also in the processnot produce disturbing noisesI tested the moving compartment in a few ways. I loadtested the compartment using everyday peripherals, suchas a laptop and external hard drive.When placed insidethe compartment is very sturdy due to the comb jointsand also the fact that the actuator is directly beneath.When placed on top the top panel slightly warps.Thiscould be due to there being no comb joints and also noreinforcement.The other way I tested the compartment was its positionbefore and after movement. I found that after it hadmoved upwards from its starting position it moves slightlybackwards. I have found this to be a result of the type ofmounting bracket I used and also the natural wobblecaused by the movement of the actuator. I have sincecorrected this by installing guide rails. I also added someheight to the actuator by adding an MDF block under themounting bracket to make the compartment flush withthe main body surface when in the down position• Performance Requirements:- The compartment must notwobbleI tested the moving compartment in a few ways. I loadtested the compartment using everyday peripherals, suchas a laptop and external hard drive.When placed insidethe compartment is very sturdy due to the comb jointsand also the fact that the actuator is directly beneath.When placed on top the top panel slightly warps.Thiscould be due to there being no comb joints and also noreinforcement.The other way I tested the compartment was its positionbefore and after movement. I found that after it hadmoved upwards from its starting position it moves slightlybackwards. I have found this to be a result of the type ofmounting bracket I used and also the natural wobblecaused by the movement of the actuator. I have sincecorrected this by installing guide rails. I also added someheight to the actuator by adding an MDF block under themounting bracket to make the compartment flush withthe main body surface when in the down positionTesting and Evaluation
    • 011.022.033.044.055.066.077.088.099.0110.00m 0s 0m 6s 0m 13s 0m 19s 0m 26s 0m 32s 0m 38s 0m 45s 0m 51s 0m 58s 1m 4sDecibels/DbTime/ m:s011.022.033.044.055.066.077.088.099.0110.0Decibels/Db0:0 00:10.207 00:20.208 00:38.603 00:48.601 00:58.603Actual Time Lapsed Time Peak Decibels Average Decibels14:45:10.029 00:00.000 57.664446 49.62900414:45:10.083 00:00.054 57.664446 47.35114914:45:10.136 00:00.107 57.664446 46.43485514:45:10.237 00:00.208 57.664446 41.11972514:45:10.637 00:00.608 57.664446 42.05751114:45:10.737 00:00.708 57.664446 41.58058114:45:10.836 00:00.807 57.664446 41.57166314:45:10.936 00:00.907 57.664446 41.19259014:45:11.036 00:01.007 57.664446 41.46195114:45:11.136 00:01.107 57.664446 42.06984714:45:11.236 00:01.207 57.664446 43.67745914:45:11.336 00:01.307 57.664446 42.88043414:45:11.436 00:01.407 57.664446 42.04865714:45:11.536 00:01.507 57.664446 42.51705614:45:11.637 00:01.608 57.664446 41.18349014:45:11.736 00:01.707 57.664446 41.01518714:45:11.836 00:01.807 57.664446 42.12834514:45:11.936 00:01.907 57.664446 40.62608914:45:12.036 00:02.007 57.664446 40.55240814:45:12.136 00:02.107 57.664446 43.63450714:45:12.236 00:02.207 57.664446 42.41674014:45:12.336 00:02.307 42.034993 41.50362514:45:12.436 00:02.407 55.477695 41.95637214:45:12.536 00:02.507 55.477695 41.75623414:45:12.636 00:02.607 55.477695 41.42753814:45:12.736 00:02.707 65.003984 57.78049314:45:12.837 00:02.808 65.003984 52.45218514:45:12.936 00:02.907 69.594695 62.67278214:45:13.036 00:03.007 69.594695 62.63789114:45:13.136 00:03.107 69.594695 51.90821014:45:13.236 00:03.207 69.594695 52.06058814:45:13.336 00:03.307 69.594695 43.23567014:45:13.436 00:03.407 69.594695 41.93967114:45:13.536 00:03.507 69.594695 41.85848414:45:13.638 00:03.609 69.594695 41.99589914:45:13.736 00:03.707 69.594695 41.47863614:45:13.836 00:03.807 69.594695 42.63488914:45:13.936 00:03.907 69.594695 40.29585614:45:14.036 00:04.007 69.594695 41.59821914:45:14.136 00:04.107 69.594695 42.66409314:45:14.236 00:04.207 69.594695 57.26742914:45:14.336 00:04.307 69.594695 46.07174614:45:14.436 00:04.407 46.743397 46.23418814:45:14.536 00:04.507 50.181794 50.17519014:45:14.636 00:04.607 81.256029 81.25602914:45:14.736 00:04.707 84.708849 65.83064314:45:14.836 00:04.807 84.708849 70.87364314:45:14.936 00:04.907 84.708849 73.75522714:45:15.036 00:05.007 84.708849 75.141116Comparison between Average and Peak VolumeVolume TestTime/ m:s:msSpeakerVolumeTestResults
    • Type Modifications Consequence ReflectionMy main material changed from pine to ash toveneered MDF. The initial change from Pine to Ashwas the natural warp due that would have been veryvisible due the length require. As I would have had tobiscuit joint several planks to get the required widththis would have made finishing a hassle to get thesurfaces completely level.Ash was a suitablereplacement as it still had a very nice finish and woodgrain and did not have this warp.The final change toAsh veneered MDF was due to the weight that thefinished product would have had if made from solidtimbers.The consequence was amuch lighter frame witha smooth flat finishIt was a necessary change tomake the overall product lighter.It also saved me time by removingthe need to biscuit joint planks tomake each panel.This thereforemakes the materials and processcosts lower and therefore canmake the product cheaper.Theonly issue is with getting the ironon veneer the correct size on theedgesAfter several attempts at forming a large acrylicsheet around the exterior of my speaker cabinetsI changed my material to HIPS due to its flexibilityA more professionalfinish with no blemishesas the HIPS was curvednaturally rather thanformed with heatThis was a good move as gettingthe desired finish using acrylicwould really have to be doneusing industrially formingmachines (e.g. injection moulding)The HIPS was much easier to fixusing impact adhesives along theedges.This has also helpedimprove the bass quality of thespeakers themselvesAfter a bit of deliberation I decided that it wouldbe best to remove the need for pulleys andreplace them with a single actuatorI have reducedmanufacturing time andalso made it muchsimpler to installThis works very smoothly. Bydoing this I have removed apotential source of error fromcable slippage or the pulleys notfunctioning as they should (e.g.the lengths are not the same)I have changed the shape of the speakers frombeing semi circular to a sector of a semi circle. Ihave also decided to only put 2 speakers (one oneach side) into the product and use the productitself for bass.A much slimmer productwith good sound qualityThis has reduced the width of theproduct and also given it an“edge” both aesthetically andphysicallyI changed my product based on a few inputs frommy client. Instead of being wall mounted it will siton the bar or in one of the hotel rooms. Ittherefore will have a compartment that goes upinstead of downLess manufacturing timespent on wall bracketsand also easy installationfor clientThis has been the trickiest part tomodify due to my initial client’sspecifications causing the productto be oversized. However, It stillfunctions very well in the sameenvironmentModificationsMaterials-MainBodyMaterials-SpeakersMechanismDesign-SpeakersDesign-MainBody
    • Type Modifications Consequence ReflectionReplacing the area for a screen with a displayspaceA thinner sheet of Ashveneered MDF could beused as the face, makingthe product lighterThis is very good as my client cannow display menus, write upmenus or even pin notices onto itin a contained areaPermanently fixed for initial prototypeThis means it will betricky to service if needsbe and cannot beinterchange with morestorage spaceThis was a decision that had to bemade as the speakers would notsit flush against the side piece dueto initial wall hanging design. It is,however, a successNo routing needed for lip and also lip is removedSaves time for processesand also make productlighter and easier to fitinto mechanismThis has saved a lot of time as therouting would have had to bespot on otherwise the entire facewould have had to be startedfrom scratch (restart jointing andcentre removal)Other way upThe product has had tobe flipped, meaningsome parts have had tobe adaptedAs this change has had to happenmid fabrication the parts aboutthe mechanism have had o changeto satisfy my new client’s needs.The bottom of the compartmentnow needs a false bottom to hidebolts and the removable face hasto go onto the bottom.Thespeakers are now permanentlyfixedAmplifier - laser cut frontA more self fulfillingcomponent thatdefinitely works with abit of added modernismThis is good as I have got aperfectly fitting front that istransparent so my client canactually see onto the circuit boardof the amplifier.This just gives it aflashy, modern touchModificationsPurpose-FrontofProductPurpose-SpeakersDesign-DropDownCompartmentPurpose-WholeProductComponents
    • Modifications During AssemblyWhat Was It? Why the Change? Picture Client ResponseAdded Guide RailsDue to the type of mounting bracket I made forthe compartment, the compartment had thetendency to jam as it would not travel squarelywith the opening in the main body. By addingguide rails the compartment will not jam due toits own movementAdded MDF StripsDue to the weight distribution of thecompartment itself the compartment would notreturn to its original position when movingdown.Therefore I used 2 strips of MDF toeffectively force the compartment into thecorrect position (without adding stress to thesides)Added MDF BlocksDue to a change is specification from my originalclient, the length of the actuator was too shortfor the compartment (when down) to lie flushwith the surface of the main body. I thereforeadded a few blocks of MDF between themounting bracket and the compartment in orderto extend the height of the actuatorUse of EVOSTIK SeriousStuff AdhesiveAfter being advised to use impact adhesive tostick my HIPS to the outside of the speakerhousings I found that the force produced by theHIPS (where the HIPS went around the curve)forced it away from the MDF after curing. Itherefore reverted to using EVOSTIK SeriousStuff. I did each housing section by section,leaving at least 12 hours between sections.Whenthe adhesive cured after 24 hours the HIPS wasfirmly in placeUse of SealantI decided to use sealant where the HIPS did notjoin the the speaker housings due to its naturalcurve when formed around the housings. I usedsealant to hide the gaps, whilst also making surethat the HIPS was secured firmly and that thefront of the speakers had a clean look
    • Questions Response Grading (10 High, 0 Low)Does the style fit the the specifiedenvironment?How easy is it to use?Does the moving compartment holdenough peripherals?Do the speakers give the requiredsound quality and volume?Would you be prepared to pay £300 forit?Can you easily access the working partsfor maintenance?Is it easy to move?Total/AverageClientQuestionnaire
    • Safety✴ All edges have been smoothed and rounded with various grades of sand paper✴ The moving compartment has no significant gaps to get limbs caught in✴ All electrics have been tested✴EvaluationForm✴ Due to changes in requirements during the manufacturing process, the product’scomponents are not interchangeable. However, if made again this is still a possibility✴ The style can be suited to all consumers. As veneered MDF was used there is a wide range ofreal wood veneers that can be chosen and with the HIPS a large choice of coloursFunction✴ The function has now change from being wall mounted to being a desktop product✴ The moving compartment can take the weight of 75 KG✴ All cables are self contained by having peripheral cables plug into a multi socket that leadsout of the product via a single cable✴ Interchangeable parts can be produced for another unit✴ Perfect for presentations - the speakers are very high quality and produce a loud surroundsound effect. The centre space can be used as a whiteboard, noticeboard or a projector screen,for example✴ Space for peripherals in compartmentUser Requirements✴ Actuator operated by simple DPDT switch✴ Speakers operated by simple volume control✴ Materials used can easily be replaced in future products to fit any environment✴ More than capable of supporting weight - actuator can take 75 KG✴ Complications during manufacturing process have meant that this product cannot be flatpacked. It can still fit into the back of a normal sized car (with seats down) and the overallweight is as manageable as any other piece of furniture. In the future components can bedesigned to be flat packed based around this prototypePerformance Requirements✴ Actuator can lift 75 KG - more than enough (perhaps objects can be on top)✴ The back and front are removable and the actuator is on a separate panel, therefore theinternal parts can easily be accessed✴ A speaker system has been integrated✴ Not battery operated - single power lead✴ The product is now over 30KG✴ Actuator removed need for pulleys and therefore reduced maintenance needs✴ There is a small side to side wobble of the moving compartment due to nature of actuator✴ Front panel can have interchangeable board typesMaterials and Components✴ The main material used was real wood veneered MDF. This not only makes the productlighter, it also means that the product has been made as eco friendly as possible by notusing solid ash✴ The real wood ash veneer has come from a source that plants at least 3 trees for everyone cutdown - This was deliberated before use due to the recent Ash Dieback disease outbreak✴ All materials have been sourced from the UK✴ If well maintained the product should last over 10 yearsQuality✴ All faces have been smoothed using various grades of sand paper and are free from glue✴ All finishes have been thoroughly inspected for the best finish possible✴ Veneer edging tape has been used to cover MDF faces and also to help adjust any skewedjoints✴ The hips has been cleaned and lightly polished for a modern look✴ Each component has been checked throughout the process for correct measurements andvisual imperfectionsScale of Production✴ This product has been made for one off production✴ It has the potential to be adapted for batch production and even mass production. This isdue to the simplicity of the mechanical/electrical elements and also the basic shapes of theother components.Size✴ The size could be a fair amount smaller. It is this size because of my initial client’s needs.✴ This product cannot be flat packed, but does not exceed 30 KG so is still fairly easy totransport via car and then deploy into a desired environment✴ There is space for a 40” screen, but a whiteboard, noticeboard or projector screen could also beemployedManufacture✴ This product cannot be flat packed, but has the potential to be adapted in future designs✴ Assembly time will be increased due to manufacturing adaptations, but simplicity ofcomponents counter this by reducing production time for individual parts✴ Product can easily be transported in the boot of an average sized car (with back seatsdown). It may require 2 people, but it weighs less than 30 KG so is no different fromlifting a table into the carEnd of life✴ MDF and other wood products are easily recycled for future craft use or for wood burning✴ Electrics are very simple. The majority is just a few lengths of cable, whilst the majorcomponents are self contained (the actuator and the amplifier). These components couldalso be reused for other purposesCost✴ My client has offered £300 pounds for my product. This was wellabove expectation (£220)✴ Total materials costs = £185PURPOSE• Create a more useable workspace by keeping cables and peripherals out of the way. It should fitinto existing environments with ease and also be self contained. Another purpose is to also havedrop down compartments and potentially a screen for storage and presentations.✴ The product is self contained, will fit into most environments and has all the functionsrequired for presentations (board;/screen area and speaker system)Use✴ Components are simple to replace as there are only 2 main parts (theactuator and the amplifier/speakers)✴ The product components should function as their individualcounterpartsSustainability✴ The main material used was real wood veneered MDF. This notonly makes the product lighter, it also means that the producthas been made as eco friendly as possible by not using solid ash✴ The real wood ash veneer has come from a source that plants atleast 3 trees for everyone cut down - This was deliberated beforeuse due to the recent Ash Dieback disease outbreak✴ All materials have been sourced from the UK✴ If well maintained the product should last over 10 yearsReferring to page 9Tech Specs:When Built-Height = 650mmWidth = 1350mmDepth = 400mmWeight = 23 KG
    • Client ResponseGood things:Issues:Conclusion:Client Change:Due to unforeseen circumstances, my client had to move away. This left me in a bit of a situation as we were working on a way of makingthe product work for his needs, whilst also mounting on the wall. However, I have found a new client, Mr Keens, who has decided to usethe existing fabrication to suit his needs
    • What went well:• The product does look like my design and CAD work• Wiring all the circuitry into a simple and more manageable form• The speakers are better than expected.The bass coming from the product as a whole is also very rich• The amplifier was a great find. Rather than buying in a cheap one online I actually got the chance to solder all the componentstogether myself. This has helped me with electrical skills• The HIPS has worked very well as an acrylic alternative.The natural flexibility helped me greatly with forming it around the speakerprofile• After having to flip the product due to my new client not wanting it to mount on the wall adapting the movement of thecompartment to work in the opposite direction as originally required has worked wellWhat didn’t go well:• The moving compartment does not quite extend fully due to a change to the dimensions of the product mid fabrication. It does makeit rather tricky to put a larger laptop in, but it does still function as required• Having to put a false bottom in the compartment has reduced the height available as space• The comb joints did fit, however during assembly the joints did not join as flush as possible.This meant a lot of finishing work wasrequired, particularly with the iron on edging veneer• Not being flat packed has made it harder to move the product in terms of lack of grip holds due to speakers being permanently fixedand also the actuator mount face being loose• Time management - I went over my personal deadline of 1/3/13.This was due to the change in processes used for variouscomponentsConclusion:Overall, the product conforms to my new client’s desired specifications.The speakers work well and the product as a whole does strike avery good first impression. In the future I would change the design of certain components to conform specifically to my new client’sspecifications.They would also be designed to be flat packed, which is made easier by knowing the ins and outs of this prototype. If madesmaller (for say a 20” screen) it would be better suited for bars and hotel rooms and would be easier to both transport and manufactureon a larger scale (with the amount of materials).My Thoughts
    • Final ProductInside CompartmentWires are self contained byfeeding out of the back ofcompartment and into themain body of the productSide of ProductOnly a single powercable required topower the unitFront