Jason Jones 090506 Innovation4extremes V1

RM: Innovation for, through, and of ExtremesBy Jason Jones & David I. WimpennyDe Montfort University
Innov_ex 09 9 May 2009

Source: http://en.wikipedia.org/wiki/Gulf_war

Source: www.byu.edu

Source: http://en.wikipedia.org/wiki/Sugarloaf_Mountain,_Brazil

RM: Innovation
through,
for,
& of
Extremes
J. Jones Innovex 09 9 May 2009

RM: Innovation
through,
Extremes

Source: http://www.notjustrocks.com/uploads/TXColmesneil8-2L.jpg

Source: http://www.notjustrocks.com/uploads/120306-6L.jpg

Source: http://www.notjustrocks.com/uploads/AZFlorence-1L.jpg

LS
Lighting + Sand =
Fulgurite (fulgurite.com)

LS
Lighting + Sand =
Laser
+ Metal Powder
+ Plastic Powder
Laser Sintering (LS)

Laser Sintering (LS or SLS)
3D Systems
EOS

Source: http://en.wikipedia.org/wiki/Amber
Source: www.byu.edu

Sap Left for Ages
SLA
Source: http://en.wikipedia.org/wiki/Amber
Source: www.byu.edu
Stereo Lithography Apparatus(SLA)

Stereolithography (SLA)
3D Systems

Terminology
SLA
LS
FDM
SLM
Jetting
SLS
3DP
LENS
USC

RM: Innovation
through,
for,
& of
Extremes

RM: Innovation
for,
& of
Extremes

Source: www.carpentertrade.com/ordering.html; en.wikipedia.org/wiki/Grip_(gymnastics)

Source: ducati.com

Pressure a helmet exerts on the head
Customized helmet
Correct helmet
Small helmet

What is Custom-Fit?
is:
A Paradigm where
Digital Manufacturing is
Driven by Customer Data in order to
Produce Customised Products for their Body

What are you going to change?
Customised liner
Padding
EPS

How to do it?
Start with a 3D helmet model in the computer
Scan the head
Morph the helmet design to fit the head
Make the helmet
Source: Custom-fit.org

3D scanning

Automated design

Result
02/05/2009

AIR
Growing Wish List
02/05/2009

(Results: failure. HIC = 2460; peak = 280G)

The Next Generation
Connecting elements
Management interface

The customer is always right.
Source: Ducati.com/ Loughborough University

Customer feedback
92% of the motorcyclists
surveyed feel discomfort from the seat when travelling long distances

Results from on line survey: motorcycle seats
Do motorcyclists want customised seats?
Customer feedback

Results from on line survey: motorcycle seats
Customer feedback
Willingness to Pay and Wait

What part(s) to change?
Aesthetics
Cover (
sky
)
Cover (
sky
)
Bottom
Pad (inside)
Comfort
Stability

How to meet customer need?
What bike part(s) to change?
The Seat
How to drive the changes?
What changes to make?
Source: Ducati.com

Unsuccessful attempts:
Scanning Measuring
Source: Human-solutions.com (far left)

Success: Empirical data from Pressure Map

What about subjective data (your feelings)?
Emperical Data (mm Hg)
Hybrid Data (Comfort Map)
Subjective Data (Feelings)
+
=
Source: IBV

Zone 3
Zone 2
Zone 1

What part(s) to change?
The Seat
Empirical + Subjective Data
Source: Ducati.com

Laboratory Stiffness testing:
Establish the dynamic performance of the standard seat material (benchmark)
Explore the performance of alternative materials

Create a “pseudo pocket sprung” seat
Using CAD & Computer Analysis (FEA) to
Hollow out the inside of the seat
Use the force vs. displacement curves from the laboratory stiffness tests to design individual “spring” like structures.

Using CAD & Computer Analysis (FEA):
Make an array of the “spring” like structures
Insert them into the seat according to…

…the customer defined Comfort Zones with the customer specified stiffness

Customised Seat making application

What bike part(s) to change?
The Seat
Empirical + Subjective Data
Graded stiffness
Source: Ducati.com

The virtual result

Digital fabrication
Validated design using: Laser Sintering
3D Systems
EOS

The result

Ducati seat
Under side
Top side

Learning Outcomes
Is the right material available?
How we will collect the data (3D scanner)?
What regulations might be barriers (CE, UL)?
Will the market pay for the added value?

RM: Innovation
through,
for,
& of
Extremes