GCSE Major ProjectResistant MaterialsMagni-hoop Oliver Leverett Centre Number 15131 Candidate Number 5669 1
PLANNING Design Process The design process is a guide I used to help me through this project. It is a industrial time process. Figure 2 Design process No. of weeks Introduction The Gannt chart allows me to have a guideline for the management of time and estimate deadlines which can refer to whilst completing my project and folder work so that I can effectively complete this project. Method I constructed my Gantt chart by identifying the main stages of development, putting them into an order that would suit the easiest and simplest way to develop my project . I used the design process as a guide on how to structure my project. I then estimated the time needed for each section. I used Exel to construct the chart to give a clear visual representation. Conclusion From this chart I can now see deadlines and the estimated time I need to spend on each section. Also I can change and update as my project develops Figure 1 Gannt chart. 2 Oliver Leverett | GCSE Major Project | Magni-Hoop
Identification of a Problem Figure 1 Introduction In this section I am going to communicate my design problem by showing some photos and some detailed annotation. This is very important because I have to present by problem very clearly to the reader so they can understand fully. In figure 1 you can see that when you have two hands full with leaves you can not place the leaves in the bag because it has folded in . Figure 2 In figure 2 you can see that the leaves have spilled out of the bag so it will take longer to be much harder to fill. This picture coincides with the picture above because the bag has folded in you can not get the full load in at once. Explanation of problem The design problem that I have when I fill up thin plastic bin bags with leaves and other materials, you need two pairs of hands to do it. Also the wind often blows the bag closed . It is almost impossible to do it on your own. Also when you have opened the empty bin bag the wind often tries to move it so you have to step on the bag while trying to collect the leaves. This makes is very hard to bend down to collect leaves and could result in injury and get your clothes covered with leaves etc. In figure 3you can see that because it is windy the bag is blown across the floor so you have to step on it to stop it blowing away . Therefore it is much harder to collect the leaves. Figure 3 Conclusion I will continue to communicate my problem and analyse in more detail with more photos and annotations. 3 Oliver Leverett | GCSE Major Project | Magni-Hoop
Product Analysis Introduction In this slide I am going to enhance my problem in more detail by using more photos and annotations, also with client opinions to help convey the problem towards the reader as well as experiencing the problem first hand by doing it Client Opinions “It is difficult to fill the bag alone, unless there is another person holding it open, I wish it was as simple as it sounds. “When it is windy, I have to step on the bag otherwise it blows away, this makes it more difficult to collect the leaves and sometimes damages the bag.” “When I try to fill the bag alone, the leaves often spill out of the sides, this means it takes longer to fill and my clothes get covered in dirt and damp from the leaves.” Client 3 Method Identifying any design issues when looking at an existing product will help me to solve any design problems that may occur or that I may need to include. Conclusion I have come up with a few initial specifications Ergonomics
Must be ergonomically sound in design so humans can easily use it .
It has got to be simple in design, compact and easy to use and be fit for purpose.
It must be easily transported and light, to allow easy storage.
It must be strong and durable.
Figure 1 As you can see the Grass is spilling out over the edge of the bag, This will make the job more difficult and make it take longer. The bag has simply collapsed inwards under the weight of the grass that is being put into the bag, (there is no rigid opening.) You can see that because the bag is flat and limp on the floor you have to bend over in a awkward position which could course back problems to many people. 4 Oliver Leverett | GCSE Major Project | Magni-Hoop Oliver Leverett | GCSE Major Project | Magni-Hoop
Design Brief and Major specifications Introduction On this slide I will show my design brief and major specifications to give a view on how my product is going to look. This is used in industry for a starting point to show clients to gather their opinions. Design Brief I am going to design a bin bag holder that is easy and simple to use to help gather garden waste. Also it has to be ergonomically sound so that people from all ages and sizes can use it comfortably. Major Specifications My product must be
Cost effective so that almost all customers can afford it.
Aesthetically pleasing so the customer will want to purchase it .
Strong and durable so it lasts and does not break after a lot of use.
Light so the customer can easily remove the holder but strong enough so it will not break during use.
Pugh’s Plates Pugh’s plates can help me with my aspects and specifications so I can refer back to them later in the project. This will aid me to design my product. Figure 1 Pugh’s Plate. Conclusion I now have a clear objective of my design brief and specifications. I will refer back to this page for the specifications I need to acquire on my product. This page will also help me to design a product that combats the problem at hand. Figure 2, Plastic bag. 5 Oliver Leverett | GCSE Major Project | Magni-Hoop
Research Plan Introduction I have produced a research plan that will help me to identify the area’s that I must address in my product. By asking the right questions I will identify all the area’s I will need to investigate . The plan gives me an organised structure to my market research. The research plan table I have constructed contains relevant questions to the design problem, also with what form of research they are and what type of information they are. This will help me produce a successful design because it will highlight the areas I must meet in my product. . . Method By looking at Pugh's plates I will be able to create a market plan that will help me make relevant questions to my questionnaire. Conclusion Now I have created my research plan I will be able to start the research, by starting on the market research. Throughout my research I will I identify the main design specifications to help focus my initial ideas. 6 Oliver Leverett | GCSE Major Project | Magni-Hoop
Market Research Questionnaire (Please put a circle around your answer) Qu. 1 Would you prefer the item to be expensive and durable rather than cheap and disposable? Yes No Not sure Qu. 2 Would you pay over £20 for the product? Yes No Not sure Qu. 3 Would you prefer plastic rather than metal? Yes No Not sure Qu.4 Would you prefer a heavier robust product rather than a lighter more mobile design? Yes No Not sure Qu.5 Would you prefer the product to be fitted with safety features so that all ages can use it? Yes No Not sure Qu. 6 Would you prefer a simple design rather than a complex one? Yes No Not sure Qu. 7 Would you prefer a more colourful, appealing design rather than a single colour design? Yes No Not sure Finally if you have any ideas or suggestions please draw or describe them in the spaces provided below. ………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………
Introduction Market research is the investigation of the current and future market. I will find out what the customer wants. And then continue my market research with a questionnaire. Method I have created a questionnaire to give to the public. By using the questionnaire I can have a greater understanding of the requirements my product needs. Also can aid with the design and manufacturing processes. Because I can see for example if people prefer a plastic material I know how my product should be manufactured. This process is used in industry so it can focus on the type of people they will be aiming to sell their product to. I planned the answers so that they could be either yes, no and not sure. I did this so it would be easy to analyse the data and would give me clear data. I have created this questionnaire to be aimed at people who are keen gardeners either as a hobby or as a job because I have identified them as my target market. Conclusion I will continue my market research with the questionnaire results, as a sample marketI have chosen gardeners because these are the main areas my product will relate. 7 Oliver Leverett | GCSE Major Project | Magni-Hoop
Questionnaire Introduction I have constructed a questionnaire to aid me to answer various questions raised in my product. I handed out my questionnaire to family and friends who are keen gardeners. Also my parents and grandparents as they do alot of gardening, and so the questionnaire covers a wide range of ages. And finally to random students at my school to get a opinion from each generation. In total I handed out 28 questionnaires. Method I gave out my questionnaire because I wanted to find out if people would use my product to help them. I did this by using my market research table. This gave me a clear idea of what questions needed to be answered. Conclusion In this slide I have collecteddata for my project that will aid me to obtain clear results. I will now go on to createpie and bar graph’s to create a clear view of what the consumer requires. 8 Oliver Leverett | GCSE Major Project | Magni-Hoop
Market Research Qu.2 Would you pay over £20 for the product? Qu. 3 Would you prefer plastic rather than metal? Introduction I have collected the data from my Questionnaire, I have created piecharts to help me understand what specifications my target market want for my product which I will develop later in my project. 69% 59% This chart shows the percentage of clients that would pay over or under £20 for the product. The clients would pay more money for a better quality product. So now I have another specification for my product. It must be high quality. The chart shows that people would prefer a plasticmaterial rather than a metal object, this might be because plastic is lighter than metal and also some metals might rust over time where as plastic does not. Qu. 1 Would you want the item to be expensive but durable rather than cheap and disposable? Qu.4 Would you prefer a heavier design rather than a lighter more mobile design? List of specifications Material
I must conceder using plastic rather than metal wherever possible, because my potential customers would prefer plastic.
I must note that people will pay more money for a better quality product.
People would rather have a product that will last a long time and be more expensive rather than an the opposite.
People want a lightweight design, so I must incorporate lightweight materials wherever possible.
50% This chart shows that the clients would prefer a lighter and more mobile design. The key specification is that it must be light and mobile. The chart shows that people prefer my product to be more expensive but stronger and more durable. The key specification is that it must be durable and strong. Conclusion From this slide I have learnt many keyspecifications. For example I must consider using plastic instead of metal wherever possible, because my potential customers would prefer plastic. I will consider to use the findings shown here to satisfy the customers requirements 9 Oliver Leverett | GCSE Major Project | Magni-Hoop
Market Research Qu. 6 Would you prefer a simple design rather than a complex ? Introduction On this page I will continue to show my market research through the use of pie charts. Qu. 5 Would you want the product to be safe enough so that almost all ages can use it ? 80% As you can see from this pie chart clients would much prefer a simple design. So the specification is that it must be easy to use. 15% 45% Qu. 7 Would you want a colourful more appealing bin bag holder rather than a basic single colour product? 40% From this pie chart you can see that most people want the product to be safe enough so that their younger child could use it. The specification is that it must be very safe for all ages to use Conclusion From this slide I have learnt I must produce a simple and easy to use, it must be safe enough so that a child could use it. it it is so be a colour-full design. As can be seen from this pie chart people would prefer a more colourful bag holder. The specification is that the product must be aesthetically pleasing. 10 Oliver Leverett | GCSE Major Project | Magni-Hoop
Existing Products Introduction In this slide I’m going to examine the existingproducts on the market that are similar to my product. I will show pictures to compare and analyse them. I will do this because so I can compact the problems related to my project. . Method I have found threeproducts from the internet and newspapers to analyse. I will analyse the advantages and disadvantages of each, which will aid me in producing a betterproduct. Fig.2 Fig. 1 Analysis 1 This product is the first of the three products I will analyse. The good things about this product are that it is lightweight so it does not become hard to use after a long time of use, also it is very simply designed so it is easilyused. The bad points are that the product can not be adjusted so it can only hold one size of bag. Also you have to tuck the bag into your chest which will be uncomfortable after long periods of time. Analysis 2 This is the second existing product I have analysed, The good points are that it is strong and relativelylightweight. Also it can hold a lot of waste and is easy to replace the bags. Also there is a large hole for the rubbish to enter. But any one of these bag holders would be very hard to manoeuvre around a building site or garden. Conclusion From this slide I have found many advantages that I will concederincorporating into my initial ideas. I will also make sure my design has none of the disadvantages that I have analysed will appear in my initial ideas. Analysis 3 This product is light and aesthetically designed because it has bright, has attractivecolours and smooth corners. The design is very simple so would be easy to use as there is no moving parts etc. But the main problem with this existing product is that it the hole for the rubbish to enter is very small, so you could not load big handfuls of rubbish at any onetime. Also it would be hard to move the holder around as there is no real place to hold it comfortably. However the circular shape of the bin lid works very well with the whole design, so I will conceder using a circular design further on in my project. Fig.3 11 Oliver Leverett | GCSE Major Project | Magni-Hoop
Product Analysis Introduction By doing an in-depth product analysis, I can I identify the problems and faults with current designs and gain a greater understanding of what my product must improve on . This will aid me to add to my key specifications as well as allowing me to see how industry combines practical properties. This table will outline the criteria as well as some questions to help provide me with the answers I need to combat the problem at hand. . . Method I have chosen a product to analyse in detail, I have chosen this product because it relates to the problem at hand, also it relates to how I want to design my product. I will analyse the advantages and disadvantages with it by analysing the function, performance, size etc. Conclusion On this page I have outlined the criteria which I will analyse in detail, In the next slide I will be starting the product analysis itself, with a very hands-on approach. 12 Oliver Leverett | GCSE Major Project | Magni-Hoop
Product Analysis: Function, Performance and Size Analysis of the size The diameter of the product is 34cm. This means that this product would notfit all bags, for example a classic black bin liner bag has a diameter of 42cm. . The clips are 3 centimetres long and 3 mm in width. The dimensions of the clips are good because the are ergonomically designed but the fact that there are only five means that the weight is not distributed evenly so there is too much stress on the bag causing rips and tears. Introduction On this page I will analyse the function of the Handihoop, I will measure how effective the clips are at holding the bag and also to see if there is any damage to the bag when it is filled. . Analysis of the performance To analyse the performance of the product I conducted a test. I filled a black plastic bag with around 10kg of damp leaves and rocks. From the picture shown you can see that the plastic bag has stretched a considerable amount due to the weight of leaves and rocks I put in. this means that if more weight was added the bad would stretch more and more until finally the bag would split and the contents would spill out. Also one of the plastic clips was damaged slightly during the process, which makes me think that clips made out of plastic could cope with the strain of long term use Finally the main body of the product did not bend or fold in any way during the experiment, this means that plastic would be strong enough to hold the bag in place even when filled with a heavy substance. . Analysis Of The Function The main functional part of the hoop is the five plastic clips around the out side of the hoop. The job for these clips is to hold the bag tightly to the Handi Hoop. The problem with the clips is simply that there is not enough of them on the hoop itself, consequently when the bag is filled with a heavy substance there is to much weight on the individual clip resulting in the bag tearing. Also the clips seem to become loose and unhinge easily. From this analysis I have learned that the product needs more clips to function to its full potential, so I will consider using more clips or holders in my final product. Conclusion I have learnt many things from this slide, I will consider putting clips onto my product, also having more than five clips so that the weight of the contents is spread evenly. And finally that plastic is strong enough to hold the bag 13 Oliver Leverett | GCSE Major Project | Magni-Hoop
Product Analysis: Cost, Ergonomics and Design Analysis of the Cost The price for the Handi Hoop is £15. This indicates that the materials that are used in the product are inexpensive but strong enough to hold a considerable amount of weight. Also from the price it can be seen that the cost of manufacture and packaging would be quite low. Finally from the price you can see that the Handi Hoop has been built to stand the test of time, it is not a disposable item. Introduction On this page I will continue to analyse the Handi Hoop project. I will analyse how the product interacts with humans, how much the product costs and why the designer has designed this product in this way. . Analysis of the Design The design of this product is very simplistic. The designer has designed the product to be very easy to use, by the way it has no real moving parts and just five plastic clips. Another very important factor that the designer has taken into consideration is weight. The Handi Hoop is very light because it is simply made of a hollow, circular plastic tube. This makes the user able to use the product for longer without becoming uncomfortable. . Analysis Of The Ergonomics The Handi Hoop interacts with humans in a variety of ways, the first and arguably the most important is the five clips that connect the bag to the holder. The clips are three centimetres long which is just under half the length of an average human thumb, this makes the clips very suited for human usage. Also the clips have a lip at the end of them to act like a hook for the thumb. Another point is that the circular tube has a diameter of two centimetres which fits into the hand very snugly to allow for optimum comfort. Finally the length of the product is big enough to allow plenty of room for rubbish to be held but small enough so that you can rest it on the users hip without any discomfort Conclusion I have learnt many things from this slide. I will consider having a light weight design to allow optimum comfort for the user, as well as having a very simple, ergonomically designed product. 14 Oliver Leverett | GCSE Major Project | Magni-Hoop
Product Analysis: Manufacturing and Materials Fig. 1 shows a diagram of injection moulding. Introduction On this page I will explore the different processes used to create my existing product and also the materials that it is made out of. . Analysis of Manufacture By examining the product I have found out that the small plastic clips have been manufactured through the process of injection moulding. Injection moulding is ideal for the manufacture of these clips because the process is very quick and tens of thousands of the exact same clip can be made through mass producing. See fig. 1 I have also discovered that the black hollow tube that fills the body of the product is made from the process of rotational moulding. This process is suited for this type of manufacture as rotational moulding is very good at making complex plastic parts. Analysis of the Materials From analysing the product I have discovered that the black hollow tube in made from low density polyethylene (LDPE). This is used in this product because LDPE has a high impact strength, so will not break during usage and will be very durable. Also it is quite a cheap plastic and is reasonably easy to shape, therefore reducing the overall cost of the product. The five clips are all made from the same material which is called high density polyethylene (HDPE). This plastic is similar to LDPE but is heavier and stronger. These characteristics are perfect for the product as the clips need to be very strong and durable to cope with the strain of a filled bin liner.
1. Granules of plastic powder (note the plastics listed above) are poured or fed into a hopper which stores it until it is needed. 2. A heater heats up the tube and when it reaches a high temperature a screw thread starts turning. 3. A motor turns a thread which pushes the granules along the heater section which melts then into a liquid. The liquid is forced into a mould where it cools into the shape (in this case a DVD storage unit). 4. The mould then opens and the unit is removed. . Conclusion From this page I have learnt what materials my existing product was made from, which I can now incorporate into my product and also how it was made which shows me an incite into how products are made in industry. Fig. 2 shows a diagram of rotational moulding 15 Oliver Leverett | GCSE Major Project | Magni-Hoop
Mood Board Introduction I will use this slide to sparkideas and to give a visualaid to my project. This slide will set a theme for my design project, and also to inspire me to create a differentdesign. Conclusion This slide has showed me that bin bags often use moulded plastic or metal in their construction, so I will consider using plastic or metal for my product. Also I will refer back to this page to help inspireme for my designsto come. 16 Oliver Leverett | GCSE Major Project | Magni-Hoop
Buzz Page Introduction The purpose of this task is to obtain new Ideas from other pupils in my class. We will do this by getting in to small groups and exchanging ideas. This process will generate a creative atmosphere for my product. By doing this I will gain a different perspective of what how my product should look. After I have obtained the sketches I need I will scan them on to this page so I can analyse them Idea number 1 Advantages; it has an adjustablehandle so it can be used by people with differentheight. Also it has wheels so it is easilymanoeuvred reducing strain on the user. Another positive point is that the product is aestheticallypleasing, this is because it has smooth,curvededges. Finally it has clips to hold the bag open.. But I think the smallwheels would not cope with the rough terrain in your garden. Method Our class were split in to groups of 3 or 4, this was to produce new ideas and sketches according to their brief and specification. We did pencil sketching and then rendered them to give a clear image of our idea. The ideas from my class mates have been given to me which I will analyse in detail, finding the pro’s and new ideas togeta new perspective from some of the sketches. Idea number 2 Advantages; it has four clips to hold the bag open without using your hands, it also has fourlegs to keep the object still and sturdy. Also the bin itself can be adjusted to fit any bag. But there are quite a few problems with this design. The product can not be moved around easily. Also it is not aestheticallydesigned, because it has sharp, pointycorners. Idea number 3 Advantages; it has a very wide base to make the object sturdy, also there is a base at the bottom of the object stopping the bag touching the floor, this stops the bag getting ripped or tared during use. The design also has clips to hold the bag open. But the product would not be easy to move around and also the bag would be hard to remove and empty once filled. 17 Oliver Leverett | GCSE Major Project | Magni-Hoop
Buzz Page- Continued Idea number 4 Advantages; This design is very compact and is easy to use, it is also easily moved around. There is a fluorescent top so you can see it under all the waste. Finally it has handles so it is easy to pull up once filled with leaves. But it would be uncomfortable to carry for a long time as there is no strap or holder for it. Idea number 7 Advantages; This design is very compact and easy to use. Also it would be very easy to carry around for a long time. Also the bag would be easy to remove once filled. But the product would be very hard to manufacture. Finally the product is has not been aestheticallydesigned, because it has sharp edges were not needed. Fig.1 Idea number 5 Advantages; it has a firm frame to keep the product steady during use. Also there is a door on the side of the object to allow easy access to the bag (for removal ) etc. But this object would be difficult to manufacture as it has moving parts that could easily brake, also it would hard to use outside because it is big and difficult to move around, finally it has not been aestheticallydesigned because it has sharp edges Fig.2 Fig.4 Conclusion From the designs I have analysed I have found out many key points . Many of the designs are too complicated, with too many moving parts, and some are two simple to perform the function efficiently, But each sketch has given me some idea of the certain problems I have to solve in the design of my product. On the next page I will generate five ideas, some of them will be inspired by some of the sketches from my buzz page. Idea number 6 Advantages; The product is designed like a foldaway table, so it is very easy for storage. Also there are four clips to hold the bag in place. But the product is not aesthetically designed because it has sharp corners , also the bag would be quite hard to remove. And it would be hard to manufacture. Finally the product would be hard to manoeuvre round rough terrain. Fig.3 18 Oliver Leverett | GCSE Major Project | Magni-Hoop
Initial idea – 1 The Cone Concept Handle to aid mobility Introduction The cone concept was inspired from my buzz page, I designed this to have a wide surface area to hold leaves and to have large and wide wheels for easy manoeuvrability. Wide opening for easy access Wheels for easy mobility Analysis The positives for this design are that the product is very manoeuvrable and is very durable. The new part I have added is a rubber stop on the bottom of my design, this is so the bottom of the bin does not get damaged when the customer puts the front end on the floor. I have moved the wheels to the back of the product because if the wheels were situated at original place it would cause discomfort to the user. The disadvantages are that once filled the bag would be hard to remove without spilling any of its contents. Also the contents would also spill out while in use as there is no lid to hold it in securely. Rubber stopper to prevent damage to bottom of cone. Conclusion From this slide I have learnt that my final product I will conceder using a lid to hold the contents securely in the bag. 19 Oliver Leverett | GCSE Major Project | Magni-Hoop
Initial idea – 2 Snug fitting clip to hold bag strongly to holder Wide opening to give easy access for rubbish. Introduction I designed this idea to be very simplistic and easy to use, it was inspired by the product I analysed in my product analysis. Analysis The advantages of this design is that it is very simple and easy to use. I have designed it so the bag will be connected to the holder by eight clips. The reason that I chose eight clips is to lessen the strain on the bag where connected to the clips during usage. Another advantage of the simplicity of the design is that the bag is very easy to remove once filled, ( undo clips and remove bag.) The disadvantages is that the holder itself is not very anthropometrically designed, the design has rough edges and would become very uncomfortable to the hands, also there is no strap the user would have press the holder into his/her hip. This would also result in pain and discomfort after a long period of use. Fig.1 CAD holder Fig 2. CAD clip Conclusion from this slide I have learnt that my product should be anthropometrically designed, so I will consider doing so in my final product. 20 Oliver Leverett | GCSE Major Project | Magni-Hoop
Initial idea 3 – Spade Concept Introduction On this page I will analyse my third initial idea, the spade concept. It was inspired by my buzz page. I will analyse why I designed it this way and also whether it has any features that can inspire me in my later designs. Ergonomically designed handle Long shaft for leverage Analysis I think this concept has an innovative design, because it can be used as a two in one product, ( as a shovel and hold waste substances.) The other advantages of this design are that It is very easy to use, as well as quick. I designed the bag holders to be as simple as possible to connect and release the bag so that when the bag is filled there is no hassle untying or un clipping that can damage the bag and spill its contents. the bag is just out from around the space. The disadvantages are that it would be very hard to get the contents from the end of the shovel into the bag without spilling the contents out of the sides. Also if the bag was filled and you put the spade into the ground to collect more waste some of the waste could slip out of the bag as the opening is facing directly downwards. Fig.1 Conclusion From this slide I have learnt that in some designs you need some complexity to ensure a product that works efficiently and correctly. I will not be taking this design any further as I do not think this design is practical. I will now go on to analyse my final initial idea. 21 Oliver Leverett | GCSE Major Project | Magni-Hoop
Initial idea 4 – Funnel Concept Fig.1 Introduction The design was inspired by my mood board, and relates to my key specifications to make sure that it combats the problem at hand. I will use detailed CAD and sketches as a visual aid to my idea. Analysis The advantages of this design are that he funnel itself is aesthetically designed, with a smooth surface and smooth corners. It is very light as it is only one piece of plastic, this means that even after a long period of time the funnel will not create any discomfort to the user. The disadvantages are that even though there are no moving parts and it is a very simple design once the funnel is in the bag it is not very stable and could tip over quite easily. Also obviously less material can be held in the funnel than can be held in the plastic bag. This means that the user will have to more loads into the bag which could cause frustration and discomfort to the user. Conclusion This design would perform its function well, however, it is not very aesthetically pleasing and is quite plain and not very innovative. 22 Oliver Leverett | GCSE Major Project | Magni-Hoop
Initial idea 5– Box Clever Concept Large hole to throw waste into. Introduction On this page I will analyse my fifth and the final of my initial ideas. I will analyze the concept of the idea with detailed CAD, annotations and sketches to help illustrate my idea. Analysis This product Is a very functional design. With a large opening for putting rubbish in and a deep storage space for waste. The reason why I think the product functions well is because of various aspects of the design; firstly There is a hinged door compartment to allow easy access for the removal and replacement of the bin liner. To aid this procedure there is a foot stomp that both opens the removal door and frees the bag from the holder to be as hygienic as possible . Although this idea would function well the design is not very aesthetically pleasing. For example The square shape is rather cumbersome and the sharp edges are not pleasing to the touch or to the looks. Also this product is not very manoeuvrable at all, therefore this idea does not fulfil my design brief as the consumer cannot carry the product around with them very easily, particularly when full. Foot stomp to allow hygienic replacement of bin Fig.1 Hinged door for easy access to bin liner for replacement. Conclusion Even though this design has given me many ideas about how my product should function I will not be taking this idea any further as the mechanism for holding the bin liner would be far too complicated 23 Oliver Leverett | GCSE Major Project | Magni-Hoop
Research: Size Fig. 1 Fig. 2 Introduction On this page I am going to research the size of my product by measuring a normal size bin liner and recording my results. This will help me to create a product that will hold almost any bag. Method To find out these measurements by conducting a few tests. I firstly measured the diameter of the top of the bag to find the total circumference, I did this so I can find out the minimum circumference of the holder I will design. After some calculations I found out that the circumference of a standard black bag is 164cm. The second measurement that I calculated was the depth of the bag, this was so I can know the minimum height of which my product must accompany for. The depth of the bag is 95cm. This picture shows me measuring the depth of the bag with a steel rule. This picture shows me measuring the length of the top of the bag to calculate the total circumference of the bag. Fig 3 Conclusion I have learnt a great deal from this section, I have learnt that product needs to over 95cm of the ground so that the bag does not rub against the floor. It must be able to hold a bag with a circumference of 164cm. This research will aid me in my development function. This picture shows a close up of the bag being measured by a steel rule. 24 Oliver Leverett | GCSE Major Project | Magni-Hoop
Development: Function Introduction On this page I will find one problem with my products functionality. I will then find three or three ways to combat this problem. I shall then pick one solution which I think is the best way to produce a better final product. Solution 1 My first solution design was inspired by the elastic bungee chords that are used to secure bikes to bike racks on cars. The good thing about this design is that is probably the strongest clip of the three that have been developed, This is because of the strong metal hooks that hold the bag to the holder. Also this design would be very durable as there are no moving parts that can easily snap of Analysis The problem I am intending to solve is how the bag is connected to the holder I am proposing to design. The problem Is that I need something strong enough to hold the bag to the holder even when filled with a heavy substance but not to allow the bag to be damaged in any way once filled. For example Velcro straps would not damage the bag but the Velcro would come apart when the bag is filled a certain level. Fig. 1 view of hooks connected Fig. 3 picture of elastic bungee chords Fig. 2 Side view of hook Conclusion Form this slide I have learnt that a bungee hook would be ideal to hold the bag onto the holder as it very strong and durable. However, the elastic would be so strong that it could put too much strain on the holder which could lead to cracks and breakages and could be potentially dangerous if it broke. Therefore I will not be taking this design any further. 25 Oliver Leverett | GCSE Major Project | Magni-Hoop
Development: Function Introduction On this page I will continue to develop the products with my products functionality. I will then find two or three ways to combat this problem. I shall then pick one solution which I think is the best way to produce a better final product. Solution 2 My second solution was inspired by my bicycle helmet clip. I think the design solution I have created is very good because it is very strong and will easily cope with the strain of holding the bag in place over a long period of time. It will also not damage the bag in any way because there are no parts that can pinch the bag, therefore this design combats the problem with my function very well. Solution 3 My third and final solution was inspired by a seat belt in a car. This design also combats the problem very well because it is very strong and would combat the problem with no difficultly. But I think it would not be needed to fill out this task because it is too big and too heavy and could put the user in some discomfort. It would also cost far more than than the plastic bicycle type clips. Analysis The problem I am intending to solve is how the bag is connected to the holder. The problem Is that I need something strong enough to hold the bag to the holder even when filled with a heavy substance but not to allow the bag to be damaged in any way once filled. For example Velcro straps would not damage the bag but the Velcro would come apart when the bag is filled over a certain weight. Fig. 1 drawing of buckle (Solution 2) Fig. 3 picture of car seatbelt buckle (solution 3) Conclusion From this slide I have learnt that a buckle from a car seatbelt would not be suitable to hold the bag to the holder as the whole concept is too big for my project. However the simple buckle is ideal for holding the bag because it is light, strong and easy to use , so I will be taking this idea forward for my first proposal. Fig. 2 CAD view of buckle 26 Oliver Leverett | GCSE Major Project | Magni-Hoop
Research: Ergonomics Introduction On this page I will research the ergonomics of my product in relation to the user. I am doing this because I want to get information on the size of human parts so that over 95% of the human population can use it. Method To aid me in my research I used a program called People Size 2000, this program is an anthropometric data base, that provides data of range peoples sizes. By using this program I can find the range from the 5th percentile of woman as the smallest woman because woman are naturally smaller than men, to the 95 percentile of men. This is where I gained some standard deviation of sizes of the human body. These pictures are relevant to my design because I need to know the shoulder height because I have designed a strap to aid the user collect leaves with maximum comfort. And I am designing a circular bin holder and I used this program to measure the grip diameter of a human hand to know the size of my holder. Conclusion From this page I have learnt that the diameter for my holder must be at least 49mm. In order to fit everybody's hand shape. Also the shoulder height in (relation to the hip) must be at least 689mm, this is so that people of almost every size can use it. 27 Oliver Leverett | GCSE Major Project | Magni-Hoop
First Proposal Introduction On this page I am going to show the CAD of my first proposal. I have taken the best aspects of my initial ideas to create my first proposal. I will show annotated my CAD work to help explain my design features. This product has wide diameter to allow easy access without causing discomfort for the user. I also did this so that the plastic bag fits around the product well and also gives the maximum sensible hole size so that a large amount of waste can be placed in at one time. Rounded edges for safety and user comfort during use. I have designed for a ridge to be cut for a strap and belt to holdbagsecurely in place. The idea is that the strap will go around the bag and tighten so that the bag does not slip or tear during usage. Conclusion I think that my first proposal design is good and I have learnt from the research and by designing this product that;
My design has to able to be able to fold or collapse flat with ease.
I will keep the circular design as it uses less material and is more aesthetically pleasing.
However there are many features that can be developed to make the product’s function more efficient and appealing. 28 Oliver Leverett | GCSE Major Project | Magni-Hoop
First Proposal Introduction On this page I am going to display my sketch work of my first proposal. I will annotate my work to make it as clear as possible showing how my product functions and how it combats the problem at hand. Method The reason I chose the plastic buckle to hold the bag is because; it is very easy to use, it is very light, and is very strong. All these aspects fit my original specifications for my design. Side view of design, showing strap around product holding bag in position View of buckle that connects bag to holder. 29 Oliver Leverett | GCSE Major Project | Magni-Hoop
Development Function Introduction To for fill the specifications from my first proposal I will have to develop the way in which my product functions. I shall do this by making three changes to my first proposal to create a better functioning product. 1. As the product had to be able to fold flat in storage I decided to start with a thin, flat rectangle (seen above.) 1st Change To allow the product to successfully fold away I must design some sort of folding or unclipping hook to allow the product to fold completely flat. I have chosen to go with a very simple and effective solution to this problem, which allows the product to be able to become flat (see fig.1) 2. 2nd Change To accommodate for the first change I have replaced the material in which the product will be made from. I have replaced the modeling plaster with a thin plastic such as acrylic (seen in fig. 2.), this will allow the product to bend easily into a circle but strong enough to hold the position it is in. This all successfully fits my specifications on my first proposal. I then incorporated a hook on one side of the product and a hole for it to connect to on the other. 3. Conclusion On this page I have combated the problem of how to store the product away efficiently. However, I have to now re-design the way in which the bag is held to the holder as the thin acrylic could not withstand the strain of a strap around it, which I shall do in the next page. The reason that I added the hook and a hole is so that the holder can easily be attached to create a circle (seen in 3) which sticks to the specification 30 Oliver Leverett | GCSE Major Project | Magni-Hoop
Development Function 2 Introduction On this page I will develop the way that the holder is connected to the user. I will explore2 ways to combat this problem and then choose one of these that I think is best suited to my product. 1st Solution The first solution is to have a strap that goes around both the holder and the user’s waist. (See fig. 1). 2ndSolution The second solution is a strap that is slung over the users shoulder. See fig 2. Fig 2 shows a sketch of the eyelets and strap. From the picture one can see that when the strap positioned in this way it allows the user to have two hands free, which is a huge advantage as many tasks in the garden need both hands for the task to be carried out. From the picture you can also see the strap is locked together by a buckle. The reason I chose this is because the buckle is the best suited design for this as it is light, strong and cost affective as I have discovered earlier in my development stage. Disadvantages The disadvantages with this design is that when the bag is filled the weight would be so great that it will cause the user discomfort as the weight is not distributed evenly around the body. Also when filled, the weight will cause the whole product to slide down the user waist down, again causing discomfort. The strap goes diagonally over the users opposite shoulder to spread the weight of the bad evenly. From this picture you can see that a single strap is used to connect the holder to the user again allowing the user to have both hands free. The strap is connected to the holder by two eye-lets that have been screwed in the acrylic. The reason I have designed this is because eye-lets are very strong and pivot around a point which is a huge advantage as the eye-lets allows people of different sizes to use the product with minimal difficulty. See fig. 3. Disadvantages The disadvantage is that the thin acrylic may not be strong enough to hold the eye-lets in place securely. Conclusion I have decided to consider to incorporate the second solution into my design, this is because the first design has too many flaws and would not be appropriate for my product. Also the second design is more suited to the task as it is stronger and more durable than the other design. 31 Oliver Leverett | GCSE Major Project | Magni-Hoop
Development Function 2. 3. Introduction On this page I will continue to develop the function of my product by designing a clip to hold the bag. I will show the changes I make in four different stages to show clearly how I have developed the function of my product 1. I first started off with this shape above. I then subtracted some material from the design so that the acrylic sheet could fit in the gap so that the bag is securely held to the holder seen here. Conclusion On this page I have clearly shown how I have developed the function of my product so that it performs overall better than my original design. I will change and finalize the size of my product in my development ergonomics page. I then added some rounds to the middle and bottom to the design so that it does not hurt anyone that uses it. This picture shows how the semi-circular clip folds down over the plastic bag. 32 Oliver Leverett | GCSE Major Project | Magni-Hoop
Second Proposal Introduction On this page I shall show close up features of my design and explain them 33 Perfect circular to identically match the clip size. Hole cut out to save weight, material and reduce costs. Thin acrylic wall so save weight and increase manoeuvrability. Clip holders spaced equidistant apart to evenly spread weight of load. Oliver Leverett | GCSE Major Project | Magni-Hoop
Second Proposal- Engineering Drawing Introduction This page will show all my product’s dimensions in a dimension drawing. This is an industrial process Oliver Leverett Second proposal 34 Oliver Leverett | GCSE Major Project | Magni-Hoop
Development Aesthetics- Shape Introduction On this page I will develop my aesthetics to create a better looking and pleasing design. Aesthetics is to do with how pleasing the product is to the five senses, for example how the product looks and feels. I will forces on the visual aspects of the aesthetics by looking at the shape and styling of the product. I have decided from analysing my design that the design in fig.1 is too square-like with too many sharp corners an is very simple and un-attractive. I have experimented with different deigns to try and give me some inspiration for the most pleasing aesthetic design. From doing these sketches I feel that example 4 (see highlighted sketch in fig.2) Is the most aesthetically pleasing of the five I have designed as it has smooth corners and looks appealing. I liked the sketch as it was practical and aesthetically pleasing I decided to design it in CAD to determine whether it would suit the function I wanted (see fig.3). I was very pleased with the results and they far surpassed my expectations for the design. It is very elegant in design with smooth curves and rounds, but I had to keep the structure strong so it would cope with the strains of hard use. I have kept many aspects of the design similar the my first design, for example I have kept the hole at the top to reduce the wait and save some material to reduce costs. 35 Conclusion On this page I have developed the aesthetics of my design by adding; more curves and rounds. I will also use this design in my final proposal. Oliver Leverett | GCSE Major Project | Magni-Hoop
Development Ergonomics Introduction On this page I will change my product so that it interacts with the user better. I will use the data from my research ergonomics page to aid me to design a more ergonomically sound product. 1st Change I have changed the height of the clip so that the bag can be changed with minimal difficulty. I have changed the height to 150mm and that is the perfect size as fits in between the 5thand 95th percentile of human hands according to PeopleSize2000. The reason I have made this change is so that people of all sizes can handle the product easily therefore creating a more ergonomically sound product. 2nd Change I have also changed the width each of the 4 parts to 15mm because I have learnt from my existing product that this size makes it very easy for the bin liner to be attached as it grips the human thumb very well see fig.2 A segment of a depth 10mm and a width of 2mm was removed as it is these dimensions that I think the acrylic sheet will be. 36 Conclusion On this page I have improved the design on my clip holder so it will interact better with the user. By making these changes I will ultimately create a better quality product. Oliver Leverett | GCSE Major Project | Magni-Hoop
Development Modelling- Second Proposal Introduction On this page I will model my second proposal design. From this page I will hope to learn which materials are best suited to my design and if the concept actually works. From analysingthe previousdevelopment stages I had decided to use acrylic as the body of my product as I think this material would be best suited to my design. However, I have to find acrylic at the right thickness so that it is; strong enough to hold a filled bag without breaking, yet flexible enough so that it is able to be bent into a circle. So I decided to test different thicknesses of acrylic to determine which thickness is best suited to my design. Fig.2 Fig. 1 I obtained three different thicknesses of acrylic of 2mm, 4mm, 6mm thicknesses as seen in fig. 1 To test the flexibility of the different thicknesses of acrylic I took one meter each piece individually and put one hand at either end of the acrylic and simply pushed my hands towards each other. The thickest acrylic of the three (the 6mm) was not very flexible at all and was also very brittle, which meant it didn’t suit any of the specifications required. The 4mm was more flexible to a point yet still didn’t meet the requirements that were necessary. However, the 2mm acrylic performed the test very well, it was flexible enough so that it bent into a complete circle as seen from fig. 2 and strong enough so that it didn’t snap. I have also decided to make the model full size as I think that this would give me the best indication whether the concept works. I will only manufacture one of the four parts on the CNC as it will save time and wont use as much Modelling plaster. Conclusion From this page I have learnt that 2mm thick acrylic is the most suited thickness for my design as it the only thickness that is strong and flexible enough to bend from a flat shape into a circular one.I shall now take this information create my second proposal model. 37 Oliver Leverett | GCSE Major Project | Magni-Hoop
Development Modelling Second Proposal Then using a steel rule I measured half way along the acrylic I had cut to accurately mark the place were the part would be glued. I then filed a 1cm gap between the two holes so fixed dowel can sllde from the larger hole to the smaller one shown in fig. 7. Firstly I cut the 2mm thick acrylic to a width of 8cm and a length of one meter using the bandsaw. Introduction On this page I will show the manufacture of mysecond proposal model through a step by step process. I will also analyse my methods of manufacture, and show photos and give reasons why I went about making the model in this way. I then placed this part into the single-holed end of acrylic so it was a tight fit. 1. 10. 7. 4. Then I loaded the CAD holders onto the MDX3P modelling software and set the CNC miller up with the correct X,Y,Z alignment. And pressed start. On the other end of the acrylic I drilled a 0.5cm hole using the pillar drill. The part was then aligned on the marked area and glued using superglue. 8. 5. 2. I then constructed a hook out of a piece of dowel with a height of 1cm and a diameter of 5 mm and glued a small circular piece of wood onto the top using a glue gun. To hold the sides of the acrylic together I drilled two holes (one with a diameter of 2cm and the other with 0.5 cm) using a pillar drill and the imperial hole cutter drills. After the job had finished I removed the part from the base of the CNC miller and prepared them for gluing. Conclusion On this page I have shown how I manufactured my model of my second proposal design. I have learnt a huge amount on how the whole manufacturing process works which I can take on further to ensure quality to final product. Next I will analyze my model to see what worked and if there is anything from this concept that I can take further into my final design. 6. 3. 9. 38 Oliver Leverett | GCSE Major Project | Magni-Hoop
Development Modelling- Evaluation Introduction On this page I will test my model ergonomically and aesthetically. By testing this I will ultimately find out if the concept of my design works well and to determine what aspects of my design need changing to produce a better quality product. Ergonomics Overall the ergonomics of the model were good, the clips were very easy to take on and off the holder see fig. 1 which proves that this aspect of the design works well and that it successfully interacts with the user. Another good aspect of this product was that the diameter of the circle was a good size to hold the bag. This is because the hole was large enough to put in large handfuls of rubbish in the bag at one time but small enough so the product is manoeuvrable and uncomfortable to hold (see fig. 2). However, the “hook and lock” mechanism that held the two ends of the acrylic together, were difficult to use as the parts used were too small and delicate to interacted with the user very well as it made the job fiddly. Function I was pleasantly surprised at how well the model performed during the tests that were conducted. the bag fitted between the clip and the holder very well. Also when I pulled on the bag from underneath the product the bag was locked securely in place (see fig. 4). However, the “hock and lock” mechanism did not for fill my expectations in holding the acrylic to make a circular shape. This is because the doe was just not strong enough to hold the acrylic in place and the only way to secure it was by gluing the two sides together using the hot glue gun. Fig.1. Fig.2. Conclusion I have learnt a huge amount from this page. I have learnt that the concept of having clips that fit over design parts functions very well. So I will conceder using clips with the holders in my final design. I have also found out things that will have to be altered to enhance the performance and function of my product. Such as redesigning the mechanism that attached the acrylic together. On the next page I will evaluate the materials that I used and if they suit the requirements my design has. Aesthetics The most attractive aspect of the model in my opinion is the circular shape, as there are no sharp corners and it is nice to the touch. but I feel that there are some things that can be done to make the design more appealing. For example the edges of the acrylic are quite rough and sharp from were they have been cut with the bandsaw which makes the design look unattractive. Fig.3. Fig. 6 shows the completed model. Fig.4. 39 Oliver Leverett | GCSE Major Project | Magni-Hoop
Development Modelling- Evaluation Material- Acrylic Out of all the materials I used in the manufacture of my model I think the acrylic performed the best throughout the tests I conducted. The reasons for this include; the width of the acrylic was just the right size to fit a human hand (see fig.2 and 3). This is very important because if the width was to large or too small it cause discomfort to the user after a period of time. In my opinion the best aspect about using the acrylic was the simplicity of storing the product. The thin acrylic allows the product to be stored flat by drilling a hole at one end (see fig. 1). Material-Modelling plaster The part made from modelling plaster performs its function well. However, I think that the CNC milled part would not be strong enough to cope with the strain of having a fully loaded bin liner for a period of time. Meaning that the design would not be durable. So the parts will have to be altered in some way to increase their strength. Another problem is that the wooden dowel I used as a hook to complete the circle just was not strong enough to hold the acrylic. Introduction On this page I will test my model ergonomically, aesthetically and I will also test if the materials I used were appropriate for my prototype and possibly even my final product. By testing this I will ultimately find out if the concept of my design works. Fig. 1 It can be seen from this picture that the hoop can be unhooked and simply placed on a nail in the wall. This means that the product takes up minimal space during storage between uses which fulfils the specification. Conclusion I have learnt a huge amount from this page. I have also found out certain aspects that will have to be altered to enhance the performance and function of my product. Such as the width of the CNC milled parts need to be redesigned go that fit the clip perfectly, that they are durable and also that they are more aesthetically pleasing. Also the mechanism that completes the circle will have to be completely redesigned but with still keeping the feature that allows the bag to be stored flat. Material- Wooden dowel It is very clear that the wooden dowel is not strong enough to take the strain of keeping the acrylic in shape. This is because I tested the dowel by hooking the acrylic onto it (like it was designed to) then I took my hands completely off the model to see if the dowel could hold the acrylic in place. And as soon I as let go the wooden dowel snapped off and the acrylic snapped back to being flat. Fig. 2 and 3 40 Oliver Leverett | GCSE Major Project | Magni-Hoop
Development Function Introduction On this page I will develop the function of my product. I will concentrate of improving the function of how the product holds a circular shape. I have learnt from my second proposal model that the mechanism for holding this shape has to be very strong but with a few moving parts as possible so that it is very easy to use and store after use. Solution 1 The first solution to the problem is to replace the single hole with three larger ones. This will spread the strain between a larger area, therefore will reduce the chances of the acrylic snapping during use. Also The three metal backward facing hooks will allow the acrylic to be firmly locked into place and will reduce the chance of the holes snapping as the pressures of use are being shared by three hooks instead of one Solution 2 Solution two uses three high strength magnets to hold the acrylic in shape. The three holes cut in fig. 2 show the housing for the magnets with the cover on and off. With the magnets on one end of the acrylic there is a steel sheet housed in material (see fig.3). When the two are bought close together the steel sheet will be attracted to the magnets and they will clamp tightly together, holding the circular shape. The beauty of this design is that there are no moving parts, just magnetism. Conclusion I have chosen to incorporate magnets into my final design as they are very user friendly and simple, which means that every age would be able to use the product. This has also never been done before, so the design can be viewed as innovative. 41 Oliver Leverett | GCSE Major Project | Magni-Hoop
Research- Materials and Finish Introduction On this page I will research what materials I will be using to make my product and why, as well as the finish I will be using. I was also describe what materials I would use if I was going to mass produce my product. 42 Fig.2 Materials and Finish The primary materials I will be making my product out of are acrylic and modelling plaster. Acrylic for the strong, flexible body of the product and modelling plaster for the long clip holders as it is durable and easy to work with. Although if my product were to be mass produced I would use Polypropoyleneand acrylic. The acrylic plastic would be formed by reacting a monomer, such as methylmethacrylate, with a catalyst. With the clips holders being manufactures by injection molding. Fig.5 shows part of the hoop that I analysed, these are mass produced from polypropylene as I would like my product to be if it was to be mass produced. Fig. 2 is a block of modelling plaster from the workshop that I will use to make my product. Mass Production If my product was going to be massed produced I would use polypropylene for the clip holders as it is a thermoplastic which is strong and durable. I obtained this information from the materials database ‘Focus on Plastics’. Polypropylene is used for many products, including the bin-liner holder I have already analysed. Polypropylene is a very robust so it the perfect material for the clip holders for my product. I will finish my product with two layers of a primer undercoat and then two layers of a topcoat of spray paint in my chosen colour. The primer will give the coat a smooth and even finish. Specifications
My product will be manufactured at school using modelling plaster and acrylic and finished with primer and spray paint.
If my product were to be mass produced it would be made from polypropylene and acrylic by injection moulding.
Fig.3 Fig.4 Conclusion I will manufacture my product in the workshop using modelling plaster and acrylic. I will then finish it using two coats of primer and spray paint. Next I will move onto research manufacture methods. Fig.1 Oliver Leverett | GCSE Major Project | Magni-Hoop
Research- Manufacture, Construction Techniques and Testing Introduction On this slide I will research manufacture and construction techniques that are suitable for my product, both as a prototype and for if it were to be mass produced. Disadvantages The main disadvantage of the CNC miller is that it uses a 6mm cutting tool, which means that any small parts that are cut are not done so with a great deal ofdetail. However, there is a 3mm drill bit that does cut small parts I more detail but the 3mm cutter cannot cut very deep into the modelling plaster. It can only cut down approximately 10mm deep compared to the 6mm’s cut depth of 50mm. It is this problem that has slightly restricted me in my design process. CNC Milling To manufacture my product at school I will primarily use the CNC miller machine, as it will allow me to make four identical parts very accurately. The CNC miller runs a 6mm drill bit cutter from a computer input, allowing it to manufacture many complex 3D parts accurately and easily. Injection Molding Process
Granulated or powdered thermoplastic plastic is fed from a hopper into the Injection Molding machine.
The screw carries the plastic along the barrel to the mould.
Heaters surround the barrel melt the plastic as it travels along the barrel.
The screw is forced back as the melted plastic collects at the end of the barrel.
Once enough plastic has collected a hydraulic ram pushes the screw forward injecting the plastic into a mould cavity.
The mould is warmed before injecting. Once warmed the plastic is injected.
The molding is left to cool before removing the plastic from the mould.
When the four parts have been manufactured I will glue them to the acrylic using super glue adhesive. I will also use filler to fill any gaps and cracks in the product to make it more aesthetically pleasing. Fig.1 Fig.1 shows the CNC miller machine in my school workshop. Injection Moulding If my product was to be mass produced the majority of it would be produced by injection moulding as this would allow it to be produced by polypropylene, a strong, low density and durable product. Injection moulding would be ideal for my product as it allows cheap, easy mass production, Also the plastic is very robust and perfect for use outside. The CNC miller will allow me to make four identical parts reasonably quickly and accurately. With the ability to manufacture parts that would be almost impossible by hand. Conclusion I will manufacture my product with the CNC miller but if I was to mass produce my product I would use injection moulding. 43 Oliver Leverett | GCSE Major Project | Magni-Hoop
Research- Minimising Environmental Impact Introduction On this slide I am going to look at how I can reduce the environmental impact of my product. When designing a product you have to consider the environmental impact it will have especially as the environment is becoming more of an issue in the public eye. Making a product that is environmentally friendly will not only have benefits for the environment but also to market the product. Specifications
When designing my product I should use as little material as possible without compromising the function and efficiency of the product.
The final product should be able to be recycled to reduce the environmental impact and reduce the products ‘carbon footprint’. Also any waste material from the manufacture if the product should be recycled and reused.
When manufacturing the product in industry a efficient process should be used, injection moulding is a good process as there is little waste produced and it uses minimal energy.
Fig.1 shows the recycling symbol for polypropylene that can be stamped onto all polypropylene products that are eligible for recycling. Recycled polypropylene can be resold and used again to manufacture other products. When designing my product I shall try and use as little material as possible without compromising the products function and effectiveness. This relatively simple step will reduce my products “carbon footprint” and will lower the environmental impact of my product. Acrylic can also be recycled and made into other products, however, this process has been seen in the past as a polluting process as it emits harmful greenhouse gasses. Although many companies such as the Shimiresearch centre have been trying to reduce the effect of recycling acrylic. Shimiis now offering a clean technology for recycling different types of acrylic scraps with high yield and low pollution load which means that acrylic can now be recycled cleanly. Recycling It is important that the final product is made of environmentally friendly materials and that the product can be recycled after its functional life. Any waste material should also be recycled along the way; at the source of the material and during the manufacture process. My final product has been designed (and will be manufactured) to be a long lasting product. I have done this so it reduces the amount of material that needed to be used compared to a ‘throw-away’ disposable item. The main material I have chosen to use is polypropylene and acrylic so I have to make sure that those two materials are recyclable. Polypropylene is easily recycled nowadays as most councils have access to a local recycling plant. Efficiency of the Manufacturing Process If I were to mass produce my product it would be manufactured through the injection moulding process. Injection moulding is widely seen as a very efficient process as it produces little waste energy through heat and there is little waste amounts of energy. This is because the injection moulding process is fast, accurate and has the ability to make identical products quickly. Conclusion This page hasinspired me to produce a more environmentally friendly product, and I will always consider the materials I am using throughout the manufacturing process. Next I will give a list of my specifications that my product must satisfy. 44 Oliver Leverett | GCSE Major Project | Magni-Hoop
The hoop must be strong, but also flexible so it does not crack and damage easily;
It must be durable so it resists everyday usage;
The product must be durable enough to withstand the elements.
The hoop must be a minimum of 94cm from the ground to allow the bottom of the bag to be elevated;
The hoop must be able to hold a bag that has a circumference of 164cm
It must be able small enough to be stored in garage of shed easily.
For my final product I will use modelling plaster, as it is strong and reasonably cheap;
I will also be using acrylic in my final product as it is strong and flexible;
If I was to mass produce this product I would use polyproplyeneinstead of modelling plaster as it is a strong plastic and can be injection moulded.
To manufacture my final product I will primarily use the CNC miller, and finish with spray paint;
If the product was to be mass produced I would use injection moulding for the clip holders and then assemble the parts to acrylic.
Introduction On this page I have presented all my design specifications that my final product must satisfy. I have picked relevant headings from Pugh’s plates to separate them. I will use this criteria to evaluate the success of my final product. Function
The product must be able to hold a bin liner on its own without human aid;
It must have a smooth mechanism to connect the bag, so it is easy and efficient to use for the consumer;
The product must be strong and durable, so it does not break easily;
The mechanism for holding the circular shape must be strong and simple, with as few moving parts as possible so it is easy to stow away;
The product should hold a circular shape without any human aid.
The product must be portable and carried with minimal effort so it will not cause any discomfort to the user during use;
It must be easy to store and must to able to store flat to reduce the amount of storage space needed.
The product must be easy to use by the consumer.
The hoop must be modern in design, so it will appeal to a wide range of users;
The colours must be bright and vibrant so that it attracts a wide range of people;
Conclusion Using the information I have obtained I can now evaluate my project. 45 Oliver Leverett | GCSE Major Project | Magni-Hoop
Final Proposal 46 Oliver Leverett | GCSE Major Project | Magni-Hoop
Final Proposal – Page 2 View of Housing for Magnets Side View Plan View Overall view 47 Oliver Leverett | GCSE Major Project | Magni-Hoop
Final Proposal- Engineering Drawing Introduction On this page I will continue to show the engineering drawings for my final design. On this page I will show the dimensions for the whole product. Engineering drawings are part of the industrial process. Oliver Leverett Final Proposal 48 Oliver Leverett | GCSE Major Project | Magni-Hoop
Final Proposal- Engineering Drawing (Individual Parts) Single clip holder covers Single clip holders Introduction On this page I will continue to show the engineering drawings for my final design. On this page I will show the dimensions for the individual parts that complete my product. Engineering drawings are part of the industrial process. Housing for steel plate Housing for magnets Conclusion On the last two pages I have shown the industrial process that is dimensional drawings, I have clearly shown diameters, lengths and radius’. 49 Oliver Leverett | GCSE Major Project | Magni-Hoop
Manufacturing plan + list of tools and Equipment Using the vernier caliper check modeling plaster, is it planed to the right thickness? Introduction On this slide I will present the manufacturing plan for my product. By planning the manufacture of my product it will reduce the likelihood of an error occurring throughout the manufacturing process, therefore improving the overall quality of my product. This plan will also give me an indication of how long each process will take to complete and help me manage my time to make sure my product is finished on time. START Using the bandsaw and the planer cut the material to the desired depth. No Yes Using double-sided sticky tape stick the modeling plaster to a sheet of plywood about 3mm bigger than the block of modeling plaster. Tools and equipment -Pro-Desktop (CAD) software
Next select three pieces of modeling plaster according to the size of the product. Design the product both with sketchs and on Pro-Desktop and export the file so it can be recogised by the CNC miller No Clamp the wood and modeling plaster in the vice to ensure it is completely flat and well stuck down to the board Sand the edges of the acrylic down using 360 grade sandpaper until a smooth curved edge appears. Model key parts of the product in styrofoam to check the product satisfies all the detailed specifications. Ensuring quality On my plan I have highlighted in red the areas where I will use quality control procedures. Repeat the modeling plaster preparation process for every part of the product that is being manufactured with the CNC miller. Obtain a sheet of acrylic the correct thickness and cut using the bandsaw to the correct length. Does the model satisfy all the detailed specifications? Conclusion The manufacturing plan will be used during the whole manufacturing process to ensure that no stages are left out. The decision cells I have created will help to ensure a good quality product as each stage will be question to see if the product is being correctly manufactured. Yes Next slide… 50 Oliver Leverett | GCSE Major Project | Magni-Hoop
Manufacturing plan + list of tools and Equipment (continued) Repeat this process or every part of the project. Introduction On this slide I have continued to present my manufacturing plan for my product. From previous slide No, return to * Export the final Pro-Desktop and export the file so it can be accessed on the MDX3P modeling software. Tools and equipment
When the machine has finished remove the part using the scraper to lift the ply wood from the CNC miller base. Is each part machined correctly with all parts fitting flush? * Yes Open the file for one part on the MDX3P software and set it up to cut from the right side, with the right depth and using the correctcutting tool. Place the cut object in the white spirit cleaning tank for 3-4 hours to remove any glue and fine dust so they will glue together easily in the next stage. Start the CNC miller cutting process. No Yes Ensuring quality On my plan I have highlighted in red the areas where I will use quality control procedures. Is the CNC miller set up correctly? Is all the modeling software set up correctly? Remove modeling plaster from tank. Set up the CNC miller, zeroing the X, Y and Z axis in the top corner of the block so that the cutter begins to cut the modeling plaster in the right place. Yes No Is there any glue still left on parts of the modeling plaster? Using the hot glue gun, glue the plywood board and modeling plaster down onto the CNC miller base. Conclusion This page shows one of the major stages of the manufacture of my project in detail. Next I will continue to present the manufacturing plan for my product Next slide… 51 Oliver Leverett | GCSE Major Project | Magni-Hoop
Manufacturing plan + list of tools and Equipment (continued) Is the product free of exposed acrylic? Then use masking tape to cover up any exposed acrylic so that the only objects shown are the modeling plaster parts. Introduction On this slide I have continued to present my manufacturing plan for my product. From previous slide Yes Place the three magnets in the three holes drilled by the CNC machine. Next use a air compressor nozzle to get rid of any dust from sanding. Tools and equipment
No Apply super glue to the chosen areas and stick the part to the acrylic making sure the parts line up flush with each other. Using contact adhesive glue parts together carefully to make sure the parts line up flush. Spray the parts with a thin coat of grey primer making sure there is an equal covering of paint. Yes Are all the measured pencil markings in the correct place? Then sand glued parts starting with 240 grade sandpaper then move onto 360 grade to get rid of any cracks or scratches in the product. Use 1200 grade paper to take the shine off the primer but careful not to take any primer completely off. Ensuring quality On my plan I have highlighted in red the areas where I will use quality control procedures. No Yes Using a steel rule and a pencil mark on the acrylic were the sanded modeling plaster pieces will go making sure they are all equidistant from each other. Has any primer been completely removed? Mix the correct amount of filler and apply to the joins of any glued areas to fill the gaps. No No Next use a air compressor nozzle to get rid of any dust from sanding. Conclusion This page shows one of the major stages of the manufacture of my project in detail. Next I will continue to present the manufacturing plan for my product When the filler has dried, use 240 and 360 to smooth the filler and further remove any imperfections in the product. Have all appropriate areas been filled properly ? Yes Next slide… 52 Oliver Leverett | GCSE Major Project | Magni-Hoop
Manufacturing plan + list of tools and Equipment (continued) Introduction On this slide I have continued to present my manufacturing plan for my product. Remove clips and line a single part up and drill one hole at every marked point. From previous slide Find a 2.5mm drill bit and attach it to the pillar drill using the chuck key. Then spray the parts with a coloured gloss top coat in a colour that suits the function and aesthetics of the product. Yes Tools and equipment
Yes No Repeat this process for all four parts. Are the holes marked in the center accurately? Does the colour suit the function and aesthetics of the product? Place clips on and screw in the cut screws using a screw driver. No Using the holes in the clips as a template, mark in the centre using a screwdriver to give a guide to the pillar drill. Yes Apply another coat of the chosen colour paint allowing the last to dry before the next coat. Then leave to dry overnight. Then remove the masking tape covering the acrylic and take of protective tape. Repeat this process for the 8 screws required. Yes Ensuring quality On my plan I have highlighted in red the areas where I will use quality control procedures. Place the product in the display stand. Then obtain 8 black screws with a 2mm diameter. Has the screw been cut at the right place? No Conclusion The manufacturing plan gives a good outline of how I should structure the manufacture of my product, but it is not final. This is because the plan may have to be altered to accommodate changes or modifications made to the design during its construction. Using a steel rule measure 8mm and mark using a scribe. Clamp the screw in the vice and saw at the 8mm mark using the hacksaw FINISH 53 Oliver Leverett | GCSE Major Project | Magni-Hoop
Diary of Manufacture Then I applied double sided sticky tape to the modelling plaster in strips so that every available space was covered to guarantee that the modelling plaster was stuck as flat as possible to the ply wood. Double sided sticky tape was used give a firm even bond between the two materials and also it is easy to remove with white spirit once the CNC miller process is complete. The first stage that I did was to find a piece of modelling plaster the right size and depth for the parts I had designed. I used a steel rule to aid me accurately measure the the dimensions Introduction A diary of manufacture is produced in industry so that a designer of manufacturer can look back at the process and make changes to either improve the manufacture techniques or make them more cost effective. On the next six pages I will introduce and describe my process through photos and detailed annotations. I will follow the same step-by-step stage as my manufacturing plan so the manufacturing process goes through a logical sequence. During the construction of my product I have stopped to try and ensure the quality as much as I can and have recorded my process by again taking as many pictures as possible. I then asked a teacher to help me plane the modelling plaster down to the right thickness with the planer/thicknesser. This was used because the modelling plaster has to be the right thickness to the dimensions required for your design. I then obtained a piece of ply wood approximately 3mm bigger than the modelling plaster. Ply wood is used because it is a lot flatter than natural wood as there are no knots or areas were the wood has warped. 54 Oliver Leverett | GCSE Major Project | Magni-Hoop
Diary of Manufacture- Page 2 Using the scalpel I removed any unwanted tape from the edges and pulled the layer of tape off. I then stuck the modelling plaster firmly on top of the ply wood. I pressed firmly to remove any air bubbles from between the tape and the modelling plaster Then the screen asked me what material I was using. I chose modelling plaster from the list given. The picture below shows the cover pieces for parts being machined I then turned on the computer linked to the CNC milling machine on. I then loaded the correct piece of work onto the MDX3P software. Then I took great detail in zeroing the X,Y and Z coordinates, as shown in this picture. After I had moved through some more steps I had been given a different screen shot. This time it asked me how far down I would like to cut. I part I had designed had a width of 15mm so I changed the depth to 15mm by scrolling the virtual wheel upwards with the mouse. Using the vice I then clamped the modelling plaster and ply wood and left it so for 30 minuets. This was to further remove any air bubbles. The software asked me what direction I wanted the material to be cut in. I chose the material to be cut downwards. Then I glued my product into place on the CNC milling machine. I ensured that the machine bed was cleaned and free of any dust before gluing down the edges using a hot glue gun. The picture below shows me about to glue the plaster down into place. 55 Oliver Leverett | GCSE Major Project | Magni-Hoop
Diary of Manufacture- Page 3 This page gave the option of a have a“draft” or “fine” cut. As the parts I were cutting were so small I chose to do a fine cut as this would give a more accurate finish and would require less sanding. I then pressed stat on the machine. To manufacture the acrylic I first measured out the right length using a steel rule and a pencil. I then used the steel rule again to set the guide on the band saw so that the acrylic was cut as straight as possible to ensure quality of the shape Once the parts were free from the tape I then glued each identical pair together using super glue. I also put the two parts onto a brass metal pole with the hole that was machined. This pole was used so I could very accurately line up the two identical parts so once glued they would be flush. I also used a scribe to get rid if any unwanted glue from around the edges. I removed the finished product from the machine using a wall paper scraper when the cut was completed. Once the acrylic was cut I used 240 grade paper to smooth of all four sides to remove the rough surfaces that were cut using the band saw. The parts were then placed in a white spirit tank (seen below) to remove the double sided sticky tape. This process would be repeated for any parts being manufactured from modelling plaster. Once this process was completed and all four parts were made I sanded the excess material and to make the part more smooth to the touch. I did this for all the parts to help ensure they were made to a good standard. I used 320 grade paper and this grade is fine enough to give a smooth finish. 56 Oliver Leverett | GCSE Major Project | Magni-Hoop
Diary of Manufacture- Page 4 Because I had glued parts together I thought it was necessary to use filer to fill in the joins to give a smooth and flush finish. Filler is perfect for this because filler is made from very fine particles that can get in to small gaps. I mixed the appropriate amount of filer with some hardener and applied the filler to any gaps or imperfections. The parts were now ready to be glued onto the acrylic, so using a steel rule I accurately marked the four areas were the parts should be glued. I placed each point equal distances apart so that the weight of a filled bag would be spread evenly. Once this glue had set I needed to manufacture the housing for the three magnets and the steel plate which were going to hold the circular shape of the hoop. I manufactured the housing of these parts from modelling plaster and repeated the process as the one previously described. The pieces were then lined up with the pencil markings on the acrylic and glued down using super glue as this made the strongest bond between acrylic and modelling plaster. After the filler had dried I used 240 then 320 grade sandpaper to smooth the areas down to further remove any imperfections. The 4 CAD designed covers were then manufactured through the CNC miller process and and were glued in the slot using super glue. 57 Oliver Leverett | GCSE Major Project | Magni-Hoop
Diary of Manufacture- Page 5 I started by smoothing the corners for both sides of the acrylic with 320 grade sandpaper so that the acrylic fitted perfectly in line with the part. Before gluing the housing for the magnets onto the acrylic I first glued the three magnets into the holes using super glue. This was so that the magnets didn’t rattle about once the cover had been glued on and also so that the magnets were as close to the steel strip as possible so that the strength of the magnetism between the two are as its highest. I then obtained some primer and shook it for approximately five minutes. The reason I used primer was so that when the final paint was applied it would give a more even finish to the product and would ensure quality. I then glued the modelling plaster covers onto the acrylic using the same process as when gluing the steel plate housing on. Then I glued the steel plate onto the acrylic using super glue. This was then followed by housing for the steel being glued around it. I used a scribe to scrape of any unwanted glue from around the joins. I then went into the spray room and sprayed my first coat of primer making sure that I sprayed every area with a even coat. I then repeated this process again to ensure that every area was primed correctly. Once the glue had set I prepared the product for spraying. I used masking tape to cover the areas that I didn’t want paint to get on. For example any bare acrylic was covered in masking tape. 58 Oliver Leverett | GCSE Major Project | Magni-Hoop
Diary of Manufacture- Page 6 Once the primer was dry I used 1200 grade sand paper to remove the top layer of the primer and to ensure all the surfaces were smooth and then chose a from the colour booklet provided. After the two coats of paint had dried I removed the masking tape and found eight screws with a diameter of 2mm. I then measured 8mm down on the screws and marked the point with a scribe. This was so I could accurately cut the screws with the same length to ensure quality. I chose a dark shade of green with a RAL number 6018 as this represents the luscious green of nature and gives an aesthetic value to the product. The paint was then applied in the same way that the primer was. The screws were then cut using a hacksaw so that they were the right length to screw into the parts. To mark the holes I used a centre punch. These holes would act like a guide for the pillar drill. The final stages were the finishing touches to the product; and paint residue or pencil marks were removed using white spirit and everything was wiped down and cleaned The depth meter was set to 55mm and the eight holes required were drilled. Then the yellow clips were then aligned in place and the screws were screwed in place using a Phillips screwdriver 59 Oliver Leverett | GCSE Major Project | Magni-Hoop
Ensuring Quality- Page 1 The pillar drill has a depth gage on it which can be used to limit how far the you can drill (see fig. 1). I used this so that I did not drill all the way through my parts and also so that the holes were cut at exactly the right depth to ensure the quality of drilling. Introduction One of my design specifications was that my product had to be a quality product. I have achieved this in ensuring quality constantly to get the best results ergonomically and aesthetically as I can. I have done this in various ways, testing materials to find which materials is best suited and through machine use and choice of finish. I sanded the modelling plaster parts with three different of sandpaper grades (240, 320, 1200) to remove any imperfections and scratches and give a more aesthetically pleasing finish to the product. To demonstrate this I have taken a picture to compare the differences between sanding modelling plaster and not (Fig. 5) From this picture it can clearly be seen that the sharp and unattractive edges of the un-sanded part (right) compared to the smooth and attractive surface of the sanded part (left). This proves that sanding helps ensure the quality of the aesthetics and shape. Depth gage Fig.1 When I cut the acrylic I used a steel rule to firstly accurately measure the distance that I wanted. I also used a guide and a clamp so that the acrylic was cut as straight as possible to ensure quality to the shape. Fig.4 Fig.2 I also filled any joins from where the parts had been glued to give a flush finish and ensure the quality of the shape. Fig.5 Fig.3 60 Oliver Leverett | GCSE Major Project | Magni-Hoop
Ensuring Quality- Page 2 When painting the product I took great care in wiping and air-spraying the product to remove any dust before spraying. If any dust were to be on the product during spraying the finish would not be even and the paint would flake off. I also took great care to not get any drips of paint from over spraying to ensure quality to the aesthetics and the the finish of the product At various stages of the manufacture I had to glue modelling plaster to acrylic, as these two materials are very different I decided to conduct tests to determine which glue had the strongest bonds between the two materials. Firstly I chose three different types of adhesive, hot glue, superglue and a two-part epoxy glue. I then glued three identical strips of acrylic (each with a different type of glue) to a block of modelling plaster. (see fig. 4) After the glue had dried I pulled each strip of acrylic to see if the glue would hold them in place in a strength test. The results (fig.5) clearly show that super glue was the strongest glues as it was the only one to hold the acrylic to the modelling plaster successfully. Fig.4 Fig.1 I also used a foam protective mat whenever I was sanding to ensure quality of the aesthetics. The foam mat stopped the product getting scratched or chipped whenever I placed it down Fig.2 Fig2. I took great care in the preparation process for the modelling plaster to be machined on the CNC miller. I clamped the modelling plaster to get rid of the unwanted air bubbles and make the modelling plaster as flat as possible. If the plaster was not straight the CNC miller would cut uneven parts which would compromise the function of my product. This was to ensure quality to the function. Fig.5 Conclusion These two pages have demonstrated how have ensured quality during the manufacture of my project. Through testing, measuring, careful tool and machine use and practical skills. Having a quality product means that it performs better, lasts longer and looks better than a product that is of a poor quality. Fig.3 61 Oliver Leverett | GCSE Major Project | Magni-Hoop
Correction of Errors My first mistake made when I was gluing a pair of the two identical parts together. As the parts were so thin and delicate it was difficult to glue them together exactly inline as the would bend very easily which altered their alignment. Also the super glue adhesive set so fast that once it was glued on incorrectly it was impossible to realign them. This part had to be filled to reduce the size of the step between the two joins. As you can see from fig.1 and 2 there was a clear step between the two parts at the join, although it is only about half a millimetre it is large enough to severely reduce the quality of the aesthetics. Also if I would have used the part how it was in the picture it would of compromised the hole function of the product. This is because the acrylic part would have not of fit in-between the space designed for it which would have dramatically reduced the quality of the build. On this page I will introduce some of the problems I came across during the manufacture of my product. I will show that mistakes can be made and also how I rectified the mistakes I made. As my product is a prototype errors were expected, as one can only learn from a mistake and move on. Fig. 1 Fig. 4 shows were the paint dried on the acrylic Before spraying my product I used masking tape to cover any acrylic so that no unwanted paint would get onto it. But in some places the acrylic was not covered with masking tape enough which meant that during spraying some of the paint seeped through the masking tape and onto the acrylic. This mistake was resolved by scrubbing the acrylic with white spirit to lift any paint and clean any dirt form the acrylic. Fig.2 Drilling the pilot holes in the modelling plaster was very difficult indeed, this was because the hole had to be deep enough to hold the screw in tightly but shallow enough not to damage or weaken the part. This hole could not be filled very easily so I had to discard the piece and start again. However, I did learn from this mistake and made sure I did not repeat the mistake again. Conclusion It is clear from the manufacture of this product that the smallest of errors can be very costly to the functionality, ergonomics and aesthetics of the product. This page shows the problems that I encountered and how I rectified them. However I was lucky enough not to have any crippling mistakes. Fig. 3 Fig. 3 62 Oliver Leverett | GCSE Major Project | Magni-Hoop
Evaluation (Evaluating the Product Against the Design Brief) Introduction The evaluation process is the last part in design and is most crucial. The aim of the evaluation is mainly to test the product and to ultimately conclude whether or not the product was a success. I will start this process by evaluating the product against my design brief. Then I will see if the product fulfilled all the design specifications, also I will hand out a questionnaire to get some users opinions of the product. Design brief To design and manufacture a bin liner holder that is aesthetically pleasing, ergonomically designed, of a high quality and is able to be used by all ages and sizes. The product must attract a wide range of people by having a modern design, that makes people want to go outside and use it. Evaluating the Product Against the Design Brief The design brief was the starting point of the entire project, it is seen to be the backbone throughout. This is why it is vital to determine whether or not your product fulfils the design brief and also if the product fulfils my clients requests by evaluating it. My brief demanded a product that has good aesthetics and an ergonomically functional design. Did my product deliver? Good Aesthetics- The vibrant colours and smooth curved surfaces has made my product 100% aesthetically pleasing. There are a few little mistakes, but none that can be seen easily. The overall look of my product looks attractive. This different colour patterns really work well with the product and the shade of green I have used represents the sense of nature and plants. The shape and finish of the product is a pure, clean and fresh look which immediately give the consumer a view of a quality product. The green contrasts with the white finish of the acrylic but does not dominate the colour scheme but adds to it. Functional Ergonomics- The housing for the clips are well ergonomically designed to make it as simple as possible to lift and close the clips. The clips hold the bin liner in place very securely as they have been screwed in tightly. The two magnetic ends are very easy to connect as there is no moving parts and there is nothing to hook or strap. Although the shape is not the perfect circle I wanted (due to the acrylic being too short) it still performs its function very well. The product can be used with all sizes and ages to a point. Every size can use it can use it if the length between their the bottom of their foot and hip is 94cm. As if they are shorter the bag will drag along the floor which will cause the bag to rip Modern Design- The elegantly curved design and colour scheme really gives the overall product a modern look. Yet it is still clear that the designed to do a specific job. Also the different three parts seem to fuse into one as they all run flush with one another which gives a modern look to the product. Conclusion The product has certainly fulfilled the design brief that I created, but now I need to find out if it will meet all the minor specifications that Imade and the user must also think the product is of a high quality. 63 Oliver Leverett | GCSE Major Project | Magni-Hoop
Evaluation (Satisfaction of Design brief and Specifications) Durability
The hoop must be strong, but also flexible so it does not crack and damage easily;✓
It must be durable so it resists everyday usage;✓
The product must be durable enough to withstand the elements.✓
The hoop must be a minimum of 94cm from the ground to allow the bottom of the bag to be elevated;✓
The hoop must be able to hold a bag that has a circumference of 164cm✓
It must be able small enough to be stored in garage or shed easily.✓
The product must be able to be used by all ages.✗
For my final product I will use modelling plaster, as it is strong and reasonably cheap;✓
I will also be using acrylic in my final product as it is flexible;✓
If I were to mass produce this product I would use polyproplyeneinstead of modelling plaster as it is a strong plastic and can be injection moulded.
To manufacture my final product I will primarily use the CNC miller, and finish with spray paint;✓
If the product were to be mass produced I would use injection moulding for the clip holders and then assemble the parts to acrylic.
Introduction On this page I will display my list of specifications and I will mark with either a tick or a cross to indicate whether or not my product fulfilled the certain specification. Function
The product must be able to hold a bin liner on its own without human aid;✓
It must have a smooth mechanism to connect the bag, so it is easy and efficient to use for the consumer;✓
The product must be strong and durable, so it does not break easily;✓
The mechanism for holding the circular shape must be strong and simple, with as few moving parts as possible so it is easy to stow away.✓
The product should hold a circular shape without any human aid.✗
The product must be portable and carried with minimal effort so it will not cause any discomfort to the user during use;✓
It must be easy to store and must to able to store flat to reduce the amount of storage space needed.✓
The product must be easy to use by the consumer.✓
The hoop must be modern in design, so it will appeal to a wide range of users;✓
The colours must be bright and vibrant so that it attracts a wide range of people;✓
Conclusion I will now explain why I think I did not meet certain specifications Oliver Leverett | GCSE Major Project | Magni-Hoop
Evaluation (Design Specification Failures) Introduction This page will show my design specifications in more detail. I will concentrate on the ones that my product failed to meet and explain why I think it didn’t fulfil certain specifications. Fig.11 The product should hold a circular shape without any human aid. There are two main reasons why the product did not meet this specification. The first is simply because the piece of acrylic I used to manufacture the product was too short. Instead of a complete circular shape being held a more of a “tear drop shape” was obtained (see fig.1) I have learnt that the shorter the piece of acrylic is the more the material “wants” to be straight. But the only way I could determine if the length was in fact too short was by completing the manufacturing process. If I could repeat the process I would try and obtain a much longer piece of acrylic so there would be less resistance for the product to be straight. The second reason is also a simple one. The magnets were not strong enough to hold the two ends of the acrylic down securely. If were to repeat the manufacturing process I would use stronger magnets and more of them, and by increasing the surface area of the pads at the ends of the acrylic to get more friction between the two pads. The product must be able to be used by all ages. This specification was meet to a point. This is because every size can use it can use the product providing the length between the bottom of their foot and hip of the person is 94cm. As if they are shorter the bag will drag along the floor which will cause the bag to rip. But children can use the product with great ease as there are no complicated moving parts to connect the bag or to connect the magnet and the steel parts together. Conclusion On this page I have suggested reasons why I think my product did not meet certain specifications. With only 2specifications not fulfilled out of the 19 set I think the product has performed well. 65 Fig.2 Oliver Leverett | GCSE Major Project | Magni-Hoop
Evaluation (Questionnaire) Introduction On this slide I will continue to evaluate my product by handing out a questionnaire, giving potential users a chance to respond to the design aspects of the product. Method I will issue the questionnaire to the people who are most affected by the design problem, those who spend a lot of time gardening or picking up waste products. I will aim to give the questionnaire to 10 people. I have allocated a box at the bottom of the questionnaire for people sketch any design improvements that become apparent to them. I have created 8 questions that I think cover all the main aspects of my design so that I gain a complete overview of my products success. Conclusion Next I will move onto the analyse the results of the questionnaire, showing them with visual representations, such as bar graphs and pie charts. 66 Fig.1 Oliver Leverett | GCSE Major Project | Magni-Hoop
Evaluation (Questionnaire) Introduction On this slide I will continue to evaluate my product by analysing the results of the questionnaire I conducted. This exercise will give me further feedback and understanding of the success of my product. I have chosen to represent my data using pie charts as it gives the data a more visual aspect. No 40% Yes 100% Yes 60% Q1: How easy was the product to use? Question two suggests that 60% people would buy the product, with many commenting on how the finish looks good and also many thought the design was innovative. However, I think that more people would have wanted to buy the product if a solid circular shape was held instead of the “tear drop” shape that occurred while trying to connect the hoop. Question four asked if they liked the modern design and how it compares to other existing products they have seen. It is clear from the results that people liked the aesthetic design of the product very much. Very Easy 20% Easy 80% No 30% According the answers form question one, all the users thought the hood was either easy or very easy to use. The main feedback I got from this question was that the bin liner was very easy to attach to the clips and that the product was light and manoeuvrable. Yes 100% Yes 70% Most people thought that the product would not get damaged even after a many periods of use. However, some people thought that the acrylic would become scratched, cracked and may possibly even snap due to the tough and demanding nature of its function. The results from question three clearly state that every person that I asked thought that the clips held the bag very strongly in place. From this I can conclude that the function in terms of holding the bag securely was a success. 67 Oliver Leverett | GCSE Major Project | Magni-Hoop
Evaluation (Questionnaire) Introduction On this page I will continue to show the results from my questionnaire using visual aids. No 10% No 20% Yes 100% Yes 80% Yes 90% Question eight was the final and arguably the most important question, I provided a copy of my design brief and let each person read it before starting the questionnaire. To my upmost delight every single person I questioned thought that the product fulfilled the design brief I am very pleased with the results of this question, this was simply because I was unsure whether or not people would like the aesthetics as much as I did. But it is clear from this pie chart that they clear thought the design was aesthetically pleasing. Question seven asked if the size of the product was the correct size for its function. Many people agreed that the size of the product was just right saying that “it is large enough to have a large opening for waste, yet small enough to be manoeuvrable and light, without being delicate and fragile. Conclusion The opinions from the users has provided me with their thoughts on my product. I have received opinions not just in Yes/No terms but all the people gave me their thoughts in their own words which will help me hugely in the improvements to my product. I can deduct from their thoughts that I have produced the product that I wanted. I have achieved a functional, ergonomic design which combines an aesthetically pleasing product. Many people found the magnet aspect of the design very innovative and different to anything they had seen before. 68 Oliver Leverett | GCSE Major Project | Magni-Hoop
Evaluation- Design Improvements Introduction On this page I will suggest possible design improvements to my product. I will use sketches as visual aids to helpcovey my designs. 69 First Improvement The first change I would make to the design would be to add a strap that goes over the users shoulder (see fig.1). This idea was originally scrapped as I thought it would make the product too heavy and bulky and it was just seemed unnecessary. But the benefits of having a strap would be that the consumer would have both hands free to cut and gather leaves and would make the product more comfortable and would make the product more user friendly. Second/Third Improvement The second improvement would be to increase the length of the acrylic (see fig.2). This would allow the product to hold its circular shape better as the acrylic would not want to fight back against the magnets as much. There is also another benefit to having a longer product, when the two ends meet a larger hole would be created which allows the user to put larger handfuls of leaves in the bag, therefore increasing the efficiency of the product. The third improvement would be to increase the amount of magnets in the design from 3 to 12. This would mean that the two ends are held together with a stronger force that will hold the shape more securely. `this would mean that the steel plate would be removed and 6 magnets put in its place. Although these improvements would add to the cost the product would function much better. Oliver Leverett | GCSE Major Project | Magni-Hoop