Design & Manufacture (Singapore) project in which we made a trekking bag with multiple functions ideal for light to medium level trekking. Volume of bag approx 40L. Trek pro™ 350S design team comprises: Uvarajan M V; Tong Jing Kai; Benjamin Quek; Shaiful

1. TrekPro™ 350S
Design & Manufacture 3N Project 2013
By: Uvarajan MVelayutham;Tong Jing Kai; Benjamin Quek; Shaiful

3. Contents of Presentation
▪ Introduction
▪ Design Process
▪ Consumer Needs
▪ QFD
▪ Final Specifications
▪ Concepts Generations
& Selection
▪ Concept Exploration
▪ Human Factors
▪ Psychology
▪ Physiology
▪ Product Differentiation
▪ Product Architecture
▪ Functional Charts & FTA
▪ Product Marketing
Potential
▪ Product Material
Selection
▪ Design for
Environment
▪ CAD Model
▪ CAD analysis
▪ Conclusion

4. Introduction
▪ Sport Engineering
▪ Trekking

5. Generic Design Process
• Manufacturing
product
Production
ramp-up
• CAD Analysis
• Design for
Environment
• Product testing
Testing and
Refinement
• Design for
manufacture
• Materials
selection
• CAD Modelling
Detail Design
• Concept
exploration
• Human factors
• Physiology
• Psychology
• Product
architecture
• Concept testing
System level
design
• Rapid concepts
generation
• TRIZ Principles
• Concept
screening and
scoring
• Concept
evaluation
Concept
Development
• Market research
• Consumer
needs
• QFD
• Final
Specifications
Planning

6. Trekking
▪ Trek Bag
▪ Items you carry for
trekking trip includes:
▪ Clothing
▪ Sleeping Bag
▪ Medical Kit with
ointments
▪ Water container
▪ Field chair
▪ Trekking pole
▪ Nesting equips
▪ Survival kits
Different item has a different function. If
we can cut down items, we can make a
more productive bag.
RealisedTrekkers require multifunction
bag.

7. Mission Statement
Mission Statement:Trekking Survival Bag
Product Description  Storage bag for trekking equipment and trip survival necessities
Benefit Proposition  Multiple functions in one bag
 Bag allows trekkers to trek independently without much aid
Primary Market  Mountain trekkers
 Military rangers
 Adventurous people venturing into inaccessible areas
Secondary Market  Casual users
Assumption and
Constraints
 Able to provide medical needs
 Aids during emergencies and evacuation
 Able to provide optimum performance in all weather
Stakeholders  User
 Retailer
 Production team

8. Consumer needs
Question/Prompt Customer Statement Interpreted Need
Typical uses I need to store my personal equipment easily into the bag. The bag can store equipment easily.
I store medical equipment needed for the trip. The bag can store medical equipment.
Bag has to be comfortable and safe to use. The bag is comfortable and safe to use.
I use the same bag for trips in dangerous trails other than in
mountains.
The bag can be used in all terrains.
Likes – Existing Bag The usage of the bag is simple. The bag is easy to use.
The bag is large enough to place most of my necessities. The bag has a lot of storage space.
The bag is light and easy to carry. The bag is lightweight.
The bag has cool design. The bag has an attractive design.
Dislikes – Existing Bag Other equipment like tents are carried by porters has no space in
the bag.
The bag can be used to carry larger items.
Not comfortable when resting with bag on. The bag can be used to rest comfortably.
It has little splashproof properties. The bag is splashproof.
The bag buckles when dropped on the ground. The bag is rigid enough to hold its shape.
Internal material if the bag tends to peel off. The bag has internal material with good properties.
The zip of the bag will open itself when overloading the storage. The bag allows storage overload.
Suggested Improvements It would be good to have heating on bag. The bag can warm the user.
Incase fall into running water, good to have a lifebuoy on bag. The bag allows the user to be buoyant in water.
No easy way to signal for help, in an emergency. The bag can signal for help in an emergency.
It is good to have water filtration in bag. The bag can filter water.
Instructions on bag for beginner trekkers will be useful. The bag will have markers on it to aid user.
The shoulder straps can have more cushions. The bag will have cushions on the shoulder straps.
The price of the bag must be cheap.
The bag is cheap.
The bag is easy to manufacture.

9. Consumer needs No. Primary Need Secondary Need
1 The bag is easy to use
The bag can store equipment easily.
The bag will have markers on it to aid user.
The bag is easy to use.
2 The bag has a lot of storage space
The bag has a lot of storage space.
The bag can be used to carry larger items.
The bag can store medical equipment.
3 The bag is comfortable to use
The bag is comfortable and safe to use.
The bag is lightweight.
The bag can be used to rest comfortably.
The bag will have cushions on the shoulder straps.
4 The bag is easy to maintain The bag is splashproof.
5 The bag is durable
The bag is rigid enough to hold its shape.
The bag has internal material with good properties.
The bag allows storage overload.
The bag can be used in all terrains.
6 The bag is lightweight The bag is lightweight.
7 The bag is multifunctional
The bag can warm the user.
The bag allows the user to be buoyant in water.
The bag can signal for help in an emergency.
The bag can filter water.
8 The bag is easy to manufacture The bag is easy to manufacture.
9 The bag is cheap The bag is cheap.
10 The bag has an attractive design The bag has an attractive design.
Hierarchy listing of Primary
needs from Secondary needs

10. QFD –
TrekPro™ 350S
Competitor Products
North Face –
Patrol 24
Berghaus –
Jalan II
Black Diamond –
Mercury 75
Deuter –
Quantum 55
Boblbee -
Megalopolis

11. Final Specifications
Metric No. Metric Units Value
1 Time to store all equipment into bag min < 1.5
2 No. of equipment that could fit in bag No. > 15
3 Fluid volume of storage in bag L > 35
4 No. of compartments in bag No. > 2
5 Thickness of padded cushions in bag mm > 10
6 Thermal conductivity of material Wm-1K-1 < 0.33
7 Elastic modulus GPa > 100
8 Mass of bag kg < 3.0
9 Material strength MPa > 30
10 No. of functions in bag No. > 2
11 Buoyancy of bag (Weight of displaced fluid L < 3
12 Cost of manufacture S$ < 100
13 No. of colour schemes available No. > 2

12. Rapid Concept Generation

13. Rapid Concept Generation

14. Concept Screening
Concept
SelectionCriteria
A
Buoyant Filter
Bag
B
Air-Bag
C
Trekking Duffel Bag
D
Stretcher Bag
E
SleepingTrek Bag
F
Boblbee Megalopolis
Bag
(REF)
Ease of Use 0 0 - - 0 0
Storage 0 - + + 0 0
Comfort + 0 0 0 + 0
Maintenance - - + - 0 0
Durability + - + + 0 0
Portability 0 - + - 0 0
Functions + + - + 0 0
Ease of manufacture 0 - + - + 0
Cost - - + - 0 0
Design + - - - 0 0
Sum +’s 4 1 6 3 2 0
Sum 0’s 4 2 1 1 8 10
Sum –‘s 2 7 3 6 0 0
Net Score 2 -6 3 -3 2 0
Rank 2 5 1 4 2 3
Continue? Combine No Combine Revise No No

15. TRIZ Principles
Principle 6 – Universality
Combining a Buoyancy tube,
field chair, water filter and
storage functions into 1 product
Principle 11 – Beforehand Cushioning
By having a buoyancy tube to aid trekker incase
of water emergency situations
Principle 30 – Flexible shells and thin films
Solid internal structure will become hollow to reduce
weight
Principle 5 – Merging/ Consolidation
Combining a wardrobe door concept onto bag
design

16. Concept Scoring
Concept
C
Trekking Duffel Bag
(REF)
AC
TrekPro
D+
Fold-a-Trek
SelectionCriteria
Weight (%) Rating
Weighted
Score Rating
Weighted
Score Rating
Weighted
Score
Ease of Use 14.7 2 0.294 3 0.441 3 0.441
Storage 8.8 3 0.264 3 0.264 4 0.352
Comfort 14.7 3 0.441 4 0.588 2 0.294
Maintenance 5.9 3 0.177 2 0.118 3 0.177
Durability 11.8 3 0.354 5 0.590 4 0.472
Portability 11.8 3 0.354 4 0.472 2 0.236
Functions 11.8 2 0.236 5 0.590 3 0.354
Ease of manufacture 2.9 3 0.087 2 0.058 4 0.118
Cost 8.8 3 0.264 2 0.176 4 0.352
Design 8.8 3 0.264 5 0.440 2 0.176
Total Score 2.735 3.737 2.972
Rank 3 1 2
Continue? No Develop No

17. Final Concept Evaluation
 Mechanisms within concepts requires
further exploration
 Exploration will be helpful for detail
designing later part of the process
 Combination of Scuba Buoyancy
Compensator, Field Chair,Water
filter and a Backpack

18. Concept Exploration

19. Human Factors
▪ Ergonomic design considerations taken
into account
▪ To make design simple so that users can
use the product safely without any
guidance

20. Anthropometrics
Male Female
Measurement
Type
(inch) 5 Percentile 50 Percentile 95 Percentile 5 Percentile 50 Percentile 95 Percentile
Measurement
Used
Mid Shoulder
Height 23.9 25.7 27.5 20.4 22.1 23.8 23.9
Hip Breadth 13.6 15.1 16.6 12.0 13.3 14.6 14.2
Shoulder 17.6 19.3 20.9 14.0 15.3 16.6 17.3
Popliteal
Height 16.0 17.5 19.0 13.6 15.1 16.5 19.0
Thigh
Clearance 5.7 6.6 7.5 4.4 5.1 5.7 5.8
5.8”
17.3” 23.9”
14.2”

21. Utility The human interfaces such as zipping the backpack, pumping water
to the storage tank of the backpack, folding and unfolding the chair
is easy to use and intuitive.Also these interfaces are relatively safe to
use.
Appearance TheTrekPro 350S has good form, line and proportion.
Orange: it’s the color tied to fun times, happy and energetic day’s
warmth and organic product. It is also associated with ambition and a
new dawn with attitude
Green: it’s the color of balance and growth. It is also very calming and
soothes the viewers
Ease of
maintenance
Hand pump can be easily maintain as the pump assembly is snap fit
The whole backpack can be wash with water and quickly dry as the
material selected is water resistance.
Low costs As the backpack outer body shell is made from Ripstop Polyamide,
the material can be easily cut and form into the shape of the frame.
The cost of sewing into the material on the frame is relatively cheap.
Psychological

22. Communication The color of orange sends strong image of ambition for the trekkers.
The whole design of the backpack communicate a sense of adventure
for the user. From the shape and the contour of the backpack the
design sends a strong message of ruggedness and durability
Water Ability for backpack to pump and filter clean water
Fatigue Excellent weight distribution ensuring that the user of theTrekPro
350s will not easily suffer from fatigue and exhaustion.
Heat Air filled cushion ensure that the user will get maximum air circulation
on his back.
Physiological

23. Product Differentiation
Light weight With a weight of 2.5 kg it’s among the lightest trekking backpack on the market
Performance features The TrekPro 350S features an integrated filter and water pump. A foldable chair for
the user to sit on
Superior ergonomics The design allows the user to carry the backpack with maximum comfort and
guaranteeing no back injury will occur.The design allows the user easy access to the
items inside the bag.
Durability TheTrekPro 350S was design to meet rigorous specification. It is design to be used
on all-weather outdoor condition.TheTrekPro 350S can also withstand temperatures
extreme and humidity.
Materials TheTrekPro 350S utilized several advanced materials to enhance both performance
and appearance.These include CFRP frame and neoprene for maximum comfort on
the shoulders.
Appearance The sleek design gave theTrekPro 350S a futuristic look associated with innovation.
Because of its aesthetic appeal and highly recognizable appearance, theTrekPro
350S is expected to be a status symbol for early adopters and creates a strong
feelings of pride among adopters.

24. Product Architecture
1. The functional elements of a product are the individual operations and
transformations that contribute to the overall performance of the product
2. The physical elements of a product are the parts, components and
subassemblies that ultimately implement the products functions.The
physical element becomes more defined as development progresses.
3. Perhaps the most important characteristic of products architecture is its
modularity.
Modularity ofTrekPro 350S
In a sectional modular architecture, all interfaces are of the same type, but there
is no single element to which all the other chunks attach.The assembly is built
up by connecting the chunks to each other via identical interfaces
In slot modular architecture each interfaces between chunks in a slot modular
architecture is of a different type from the others.

25. Product Architecture
Physical ElementFunctional
Element
Storage of items
Pumping of
clean filtered
water
Chair for user to
sit on
Foldable Chair
compartment
Water pump
Sternum Strap
Zippers
Bag Cushion
Area
Buoyant
Tube
Buoyancy force

26. Functional Flow Chart -Water Pump
Placed filter onto
water source
Used hand to
generate pressure
on Squeezer
Water will flow
through hose by
the pressure loss
generated by the
squeezer
Water will flow
into the hydration
pack
Turn knob
clockwise
Used hand to
generate pressure
on Squeezer
Dirt will flow out
through release
valve
Filter
Squeezer
Water flow to
storage
Release
valve
Knob
Dirt Cleaning

27. Functional Flow Chart - Foldable Chair
Foldable Chair in closed position Foldable Chair in open position
Placed backpack
firmly on flat
ground
Used hand to
open chair
Secure foldable
chair at 90
degree position

28. Function-Storage
Primary Storage
compartment,
opened and closed
by Zipper
23L
Secondary Storage
compartment,
opened and closed
by Zipper
5L Side storage
compartment,
opened and closed
by Heavy Duty
Velcro
1.5L x 2
Top storage
compartment, Quick
Access opened and closed
by Heavy DutyVelcro
5L
Bottom Storage
compartment, opened
and closed by Heavy
DutyVelcro
4L

29. Function-BuoyantTube
BouyantTube

30. Implications of design on architecture
Product change Since the outer body of the bag is made of fabric, the styling of the backpack can
be easily modified for different target market segments
Product variety Different variety can be manufactured without increasing the cost of production
as the outer body shell is made soft fabric.
Component standardization Zipper, sternum straps, heavy duty velcro
Product performance -ability to hold 40kg of load
-ability to pump and store clean filtered water
-integrated foldable chair for the user to sit on
Manufacturability -internal frame of the bag made from CFRP can be easily manufactured
- the body of the bag made from RipStop Polyamide can be easily shaped and
sewed to the bag

31. Platform Planning
(Differentiation plan)
Differentiating
Attributes
Trek Pro Trek Pro
Lite
Trek Pro
Student
Chair
Water Pump
- -
-

32. FaultTree Analysis (FTA)

33. Material Specifications and
Selection
 Promotional
poster of Product

34. TrekPro™ 350S Layout
•Fabric
Covering
•Buoyant
Tube
•Bag Strap
•Air Cushion
•Seat
•Internal
Frames

35. Selected materials forTrekPro™ 350S
Fabric Covering
▪ Ripstop Polyamide 210DHD
(Outer and inner Material Fabric)
Bag Strap
▪ Ripstop Polyamide 210DHDWith Neoprene
Buoyant tube
▪ Air Inflated
▪ (Outer Layer 1680 Denier Ballistic Nylon) Fused with (Inner Layer 420 Denier Nylon)

36. Selected materials forTrekPro™ 350S
Convertible Seat
▪ PolybutyleneTerephtalate infused with 30% Carbon Fibre (PBT 30% Carbon Fibre)
Internal Structural Frames
▪ Carbon Fibre Reinforced Plastic CFRP
Lumber Pad Cushion
▪ (Outer Layer 1680 Denier Ballistic Nylon) Fused with (Inner Layer 420 Denier Nylon)
▪ Neoprene

37. Material Selection for Frame

38. CFRP vs. Aluminum Silicon Carbide
Properties to be weighted between CFRP and
Aluminum Silicon Carbide:
•Weight
•Fracture toughness
•Cost
•Tensile strength
•Machinability

39. CFRP vs. Aluminum Silicon Carbide
•Table shows that CFRP is better than
Aluminum Silicon Carbide
•Hence CFRP was chosen

40. Material Properties
CFRP (FRAME)
▪ Extremely strong and lightweight
▪ High strength and rigidity
▪ Corrosion resistance
▪ Eco friendly
▪ High damage tolerance

41. Material Properties
PolybutyleneTerephtalate, PBT (30% carbon Fibre) (SEAT)
▪ Widely available
▪ High strength and stiffness
▪ Good creep durability under thermal stress
▪ Corrosion resistance
▪ High heat deflection temperature
▪ Eco friendly

42. Material Properties
Ripstop Polyamide 210DHD
▪ Recycled waste material (Eco friendly)
▪ Extremely lightweight
▪ UV radiation resistance and water resistance
▪ High resistance to ware and tear
▪ Cheap
▪ Readily available in the market

43. Material Properties
Sternum Strap
▪ Fast release
▪ Cheap
▪ Lightweight
▪ Readily available in the market

44. Material Properties
Neoprene
▪ Lightweight
▪ Excellent good impact absorber
▪ Weather andWater resistance
▪ Low friction
▪ Elastic and form-fitting

45. Material Properties
Brass
▪ Used for zippers
▪ Corrosion resistance
▪ Appealing
▪ High strength

46. Material Properties
1680 Denier Ballistic Nylon and 420 Denier Nylon
▪ Abrasion and corrosion resistance
▪ Bullet proof (Being extremely high strength)
▪ Water resistance
▪ Able to stretch
▪ Durable
▪ Eco friendly

47. Material Properties
Heavy DutyVelcroTape
▪ High adhesive strength
▪ High adhesion
▪ High tensile strength
▪ Weather and temperature resistance
▪ Cheap
▪ Eco friendly

48. TrekPro™ 350S
Layout with material
FrontView

49. TrekPro™ 350S
Layout with material
BackView

50. Material Pricing
Material Cost Volume Total Unit Cost
CFRP
SGD 6 – 80 / piece
Min 300 Pieces
250
500
1000
$50
$20
$12
PBT (30% Carbon Fibre)
SGD 2.30 - 4 / Kg
Min 1000Kg
250
500
1000
$4
$3
$2.50
Ripstop Polyamide 210DHD
SGD 1 – 2 / Meters
Minimum 500 Meters
250
500
1000
$2
$1.50
$1
Sternum Straps
SGD 1 – 6 / Piece
Minimum 500 pieces
250
500
1000
$8
$6
$1.50
Neoprene
SGD 6.62 – 7.28 / Kg
Minimum 250Kg
250
500
1000
$9
$7.50
$6

51. Material Pricing
Brass Zippers
SGD 0.01 – 1 / Piece
Minimum 100 Pieces
250
500
1000
$0.50
$0.25
$0.10
Ballistic Nylon
SGD 1.2 – 4 / Meters
Minimum 500 Meters
250
500
1000
$6
$4
$2
Denier Nylon
SGD 1 – 3 / Meters
Minimum 500 Meters
250
500
1000
$4
$3
$1.50
Self Adhesive VelcroTape
SGD 0.01 – 1 / Meters
Min 3000 Meters
250
500
1000
$0.80
$0.50
$0.30

52. Brief summary of financial analysis
•Total cost of materials: $22875
•Total operating expenses: $9900
•Total manufacturing cost (500 units): $32775
•Cost per unit: $65.55
•Expected profit margin estimated to be 200%
•Expected cost per unit: SGD$199.90

53. Drafting forTrekPro™ 350S
Frame Draft  SolidWorks Surface Modelling  CATIA

54. CAD Drafting Frame (Close)

55. CAD Drafting Frame (Open)

56. CAD Drafting Surface

58. Assess energy/CO2 Over
lifespan of
Material
• Minimize raw
material usage.
• Raise material
recycle
awareness
Manufacture
Minimize
• Process energy
by selecting the
correct
manufacturing
process for the
material.
• Energy/CO2
Usage
• Material
Wastage
Transport
Minimize
• Distance travel
• Transportation
method
Disposal
Select
• Non-Toxic
materials.
• Recycle material.

59. Manufacture Energy Eco-Audit for Material
Component Material Process Amount processed Energy (MJ) %
Seat PBT (30% carbon fiber) Polymer molding 2.8 kg 54 48.9
Seat
ABS (20% carbon fiber, EMI
shielding, conductive)
Polymer molding 2.8 kg 56 51.1
Total 1.1e+02 100
Component Material Process Amount processed Energy (MJ) %
Frame
CFRP, epoxy matrix
(isotropic)
Resin spray-up 1.8 kg 27 59.2
Frame
Aluminum/Silicon carbide
composite
Casting 1.8 kg 18 40.8
Total 45 100

60. CO2 Eco-Audit for Material
Component Material Process Amount processed
CO2
footprint
(kg)
%
Seat PBT (30% carbon fiber) Polymer molding 2.8 kg 4 48.9
Seat
ABS (20% carbon fiber, EMI shielding,
conductive)
Polymer molding 2.8 kg 4.2 51.1
Total 8.3 100
Component Material Process Amount processed Energy (MJ) %
Frame
CFRP, epoxy matrix
(isotropic)
Resin spray-up 1.8kg 27 59.2
Frame
Aluminum/Silicon
carbide composite
Casting 1.8kg 18 40.8
Total 45 100

61. WhyTrekPro™ 350S is a Eco Design?

63. DropTest Analysis (Stress)

64. DropTest Analysis (Displacement)

65. DropTest Analysis (Strain)

66. Sitting Analysis@1000N (Stress)

67. Video of the Sitting Analysis@1000N (Stress)

68. SittingAnalysis@1000N (Displacement)

69. Sitting Analysis@1000N (Strain)

72. Original LifeStraw®

73. Modification on LifeStraw®.
1
2
3
4
5

75. AirTraps

76. Volumetric Shrinkage

77. Weld lines

78. Sink Marks Shaded

79. Deflection,All Effect

81. How good isTrekPro™ 350S?
Metric No. Metric Units TargetValue Actual Value Fulfilled?
1 Time to store all equipment into bag min < 1.5 Nil
2 No. of equipment that could fit in bag No. > 15 Nil
3 Fluid volume of storage in bag L > 35 40
4 No. of compartments in bag No. > 2 6
5 Thickness of padded cushions in bag mm > 10 15
6 Thermal conductivity of material Wm-1K-1 < 0.33 0.24
7 Elastic modulus GPa > 100 150
8 Mass of bag kg < 3.0 2.5
9 Material strength MPa > 30 35
10 No. of functions in bag No. > 2 4
11 Buoyancy of bag (Weight of displaced fluid) L < 3 Nil
12 Cost of manufacture S$ < 100 65.55
13 No. of colour schemes available No. > 2 5
TrekPro™ 350S has met 77% of the targeted final specifications set for it