A I D A N H A R R I S O N

A level product design

Ideas

One of my ideas is for Mrs Hardie as she needs a transportable display unit for her broken MacBooks. The idea I came up with is to have it like a sewing box so that you can open it and show students them but then also transport it easily.

The second idea is for my Grandad who is a music teacher and needs some stands for his instruments that can be taken apart and reassembled easily or that fold up.

In conclusion I am going to be doing the idea for my Grandad as I feel it has more potential after I've made and feel as a product it can be extended further and I believe he will be a good client.

Clients background

Name: Howard Harrison Age: 61 Job: Music teacher and leader of a samba band Hobbies: Music and photography Skin-tight samba : The product I have been asked to make is for skin-tight samba

which is a samba band that is based near Taunton in Somerset. Skin-tight samba is a 16 piece Samba Band they play classic Brazilian grooves and other rhythms adapted or created for Samba instruments. My client is the person that runs the whole band and their business he also is the lead teacher of the band.

Band base: The Baptist Church Hall, South St, Wellington Somerset Product environment : I will be interviewing my client to get information about

the environment it is going to be in such as the car and where they perform and practice.

Gigs : My client said “Gigs & Workshops. First of all, Skin-tight is a not-for-profit 'community' organisation, so it charges on order to cover its costs (that includes buying and repairing instruments, hiring a rehearsal space and so on), but otherwise keeps charges to a minimum. Even then, the answer isn't totally simple because we charge more for some gigs than others - we did one the other night to help raise money for the South-West Children's Hospice and wanted to support it as much as we could so we did it for free. We sometimes get asked to play for weddings and parties and charge about £350. For other things we charge somewhere in between”.

Situation and brief

Situation

In the email above my client has identified that the gongs are the most difficult instruments to support whilst performing. The gongs are up to 2 foot wide so I will need to make sure my stand is the correct size also they need to be up to 5 feet tall obviously so its at the right height for the players. He has explained to me that they need to fold down inorder to fit in his car and be transport from gig to gig. They also must be lightweight but strong so they can be carried easily but still support the gongs, they also need a base that will support the weight and movement of the gongs. I understand that he doesn't want to fiddle about with bolts every time he has to assemble it. An idea for the base would to have a heavy base that kept the gongs weighed down.

Brief

I propose to design and manufacture a product that will solve my granddads problem and meet his requirements. I will be making a stand for his gong that is easy to put together and easy to pack away. I plan on doing this by making the stand foldable so it becomes smaller as that was another requirement as it has to be transported in a car so will need to be as small as possible.

Email from my client

Time plan1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19

Mind map

Situation & brief

Research plan

Mood board

Research

Research analysis

specification

Design proposals

Development

Modelling

Plan of manufacture

Manufacture

Testing

Modification

Evaluation

Doing a time plan is very effective as it will allow me to make sure I stay on track during the project in order to

finish on time.

Research plan

What I need to find out

Sources Why I need to find it out

Existing products

I have been using sound travels website and Google shopping to find existing products.

I will be researching into all the products similar to what I have been asked to make to insure that I understand the problems with the existing products. This will effect my designing process and will make me understand more about what I am making.

Materials I will be looking at materials commonly used for gong stands and looking on the CD romplayer at resistant materials for information.

By researching into materials it will give me a greater understanding of what my product needs to be made of, this is important for my product as it needs to support the gong so I must be careful choosing materials as it needs to be a supportive material.

Fittings Will be looking on the internet to find the best fittings to join parts of my design.

I have been asked to make it fold up as small as possible so an idea I hade is to use fittings that all the pieces are connected but still fold effectively and maintain its shape when together. So I will need to look at the appropriate fittings.

Productiontechniques

Will be talking to my teachers and Mr. crew to identify what equipment would be best.

I will need to research into how I am going to manufacture my product so that when it comes to the making I will know what machines or methods I am going to use to produce it.

Questionnaire I will use survey monkey to create a questionnaire that my client can give to his band.

This questionnaire will allow me to get an understanding of how other members of the band want my product to be designed. Also I can gain information about colour schemes and anthropometric data.

Moodboard

Context analysis

Existing products

Product Aesthetics Customer Cost Size Safety Environment Function Manufacture

It doesn't have any specific designs its simply made for function.

People who play the gong or need it for a band or educational.

£89.99 54” tall by 42” wide which can shortened to fit different gongs so this is a good feature as it makes it useable for more than one size.

It has lock on wheels so that it will stay stable when neededbut can be moved aroundefficiently.

Looks smooth and wouldn't cause any problems in a musical environment.

It is used to support the gong as it is being played so it must be sturdy to hold them as they are fairly heavy.

It is made from solid steel which can withstand the weight of a gong. The use of the wheels allows it to be moved around easily. They have used bolts that you use to dismantle it.

This stand has nice cultural influences from china where the gong is from.

People looking for a more aesthetic product rather than function and more money.

£100 Can hold gongsfrom 40-60cm so is handy for someone with multiple gongs of different sizes.

Looks well varnished so is protected and also wouldexpect it to have been sanded so will not have any splinters.

Doesn't look like it would have any splinters looks well varnished so will not cause any problems when people are interacting with it.

It looks sturdy enough to hold the gong in place while it is being played.

It is made from wood and comes in 4 pieces but looks quite difficult to dismantle. Unlike the other one you would have to carry it as it has no wheels.

This standlooks quite flimsy and fiddly as it has many bolts.

People who are looking for a cheap stand and might have just started playing

£38 The stand can be adjusted from 34inches to 80. It has two interchangeable bars so not as adjustable as others.

It looks smooth and would not cause any issues to the user.

Looks lightweight so can be moved around its environment easily.

It looks like it does its functioneffectively and would support the gong but not sure on its strength.

It is made from plasticwith metal fittings so might be slightly flimsy. Unlike the top one it has no wheels so maybe this is why its made of a lighter material so it can be transported easier.

This stand looks very nice as its varnished well and is a nice shape.

People with a lot more money looking for something durable and effective

£285 Height: 157 cm Width(at top) 109 cm / Width (at bottom) 148 cm. It can hold gongs up to 115 cm big which is very large and can also hold smaller so is very effective.

Looks very smooth and varnished well as it is a high quality product and will cause no problems to the user.

Doesn't look particularly heavy so can be moved in its environment easily.

It looks very efficient and looks like it would support the gong well.

It has been made from beech wood which is a very nice looking wood it also has a high shock resistance which is perfect for this product.

Product analysis

Aesthetics – this stand is quite a simple shape it is made for guitars and has good foam stoppers so they do no scratch the instruments.

Customers – this is made for people who are looking for a stand that safely supports this guitar while they are not using them.

Size – the stand is 72cm tall and 61cm wide and supports five guitars.

Safety – the foam stoppers are a safety aspect as they protect the instruments. It also has feet at the bottom so it does not scratch the floor.

Environment – it is made out of stainless steel so does not scratch and can be reused.

Function – the product is used to support guitars while they are not being used it does this safely. It is also adjustable in height and can fold but you have to fiddle with bolts which isn't ideal.

Manufacture – it has been drilled into to create holes for the bolts, it has also been bent so this makes the product weaker.

Quality – it is quite wobbly so has clearly not been made for a long durability and may be a budget stand.

Materials research

Beech wood is used for cabinet and furniture making, work benches, desks, chairs, turnery, tool handles, mallets, decorative veneers and domestic flooring. This wood would be good for my product as due to its previous uses it is good for support and people interact with it often. Because it is a hard wood and is strong it will support the gongs.

Pine wood is used for furniture making, joinery, building construction, telegraph poles and plywood. This would is a lot more accessible to the school and it comes at a cheaper price. It is also easy to apply a finish to.

Ply wood is used for furniture making, carcases, cabinet backs, drawer bottoms and panelling. It would be good for production as I can cut it using the CNC router which will allow me to have a more interesting design by using pro desktop to create it. It is also suitable for exterior work which my product might occasionally endure. It also finishes well so I can change its appearance easily.

Stainless steel has been used in many music instrument stands before as it is strong and good for supporting the instruments. It can be cut out by machine so would be good for production. Stainless steel doesn't rust so would be good to use for outdoor performances. It can be bent as well so I will be able to make it into different shapes. It is malleable and this means it will be easy to work with.

Beech wood

Pine wood

Ply wood

Stainless steel

Fittings (materials)

Using a hasp and staple will be useful in my product as it will allow me to join two pieces of wood together and they will still be secure this will help as my client wants his stand to be able to fold up small and still be assembled easily.

The connector is made from ABS and was made on the 3D printer and would be very useful if I were to design something similar to connect various parts of my stand such as the top bar.

ABS is a thermoplastic that is often used where impact resistance is an important design consideration. It can be moulded into any shape in many ways if I were to use this material for certain aspects of my product I would use the 3D printer to produce this.

Hasp and staple

ABS connector

ABS

Production and machines

The CNC router is what I would use to cut out my work because it can cut wood up to 21mm which will allow me to use such thickness and this will increase the stability of my stand. It also has a very large cutting area so I will be able to cut out many components at a time.

The 3D printer will allow me to make connectors like shown on the previous slide which will be very sturdy and precise. These connectors will allow my product to be assembled and dismantled easily without using loads of bolts like my client requested.

I will need to use the belt sander to insure that the wood is smooth and will not give the user any splinters. This also makes the wood look a lot nicer. Also if I need to shorten the length or width of a component the belt sander will allow me to do so.

Survey

1. They are too hard to assemble as they come equipped with nuts and bolts that join the stand together, this is bad because they are easy to misplace especially when travelling a lot.

2. Medium – they are not hard to fit in the car once packed up but packing them up is the main problem and there is also room for resizing so they are easier to fit in.

3. Yes- this would be a good idea as it would make packing up a lot easier and depending on the size could save a lot of space in the boot.

4. Wood – for the main stand I think wood would be nice aesthetically and is different to the metal stands used in the band at the moment.

5. 95cm – as this is in between the women's height and the men's height so seeing as there is a variety of genders who use the stand it would logical.

6. I would like it to have its natural colours if using wood and to be finished with a varnish so that it is protected from damage.

7. Yes - it would be very nice to see the band logo on their so when we do performances it makes us look more professional by having personalised equipment.

Context analysis

Slide 9 – in this slide I have learnt a lot about the products that are already out there I can now decide what material I need to use I can also understand more about the problems that my client may be having with the existing products.

Slide 10 – in this slide I have understood physically what the issues are with products like the one my client has identified this will help me to make my product more suitable in the designing stage.

Slide 11 – doing research into the materials i may be able to use has given me a clearer understanding of what will be suitable for my product and has made me think about looks and durability.

Slide 12 – in this slide I have identified which will be the most successful ways of joining my components so that the product will folds up as small as possible this was useful as my client had requested his as a key part of the products criteria.

Slide 13 – doing research into the machines I can use has given me a much clearer idea of what I will use to produce my product which gives me a clear plan for manufacture.

Specification Function – I am designing a stand for a gong, the stand must be easy to assemble and dismantle with out the use of nuts and bolts. •The reason why I am not going to be using nuts and bolts as my client has outlined this as being the problem with the current products available, he needs the product to be able to fold up as small as possible and fit in his car boot. •The product needs to have connectors allowing it to be assembled quickly and still withstand the impact of use.•It will need to be a stable product as it will be withstanding lots of impact while the instrument is being played, it also needs to be able to hold the instrument.User – The product I will be producing is for my clients band so he will not be the only person interacting with it so it needs to be suitable for all the people who play the instruments with in the band.•I will not be marketing this product and it doesn't necessarily solve a broad problem this is mainly very specific to the band and my client. Human factors - My product needs to be at a comfortable height for the average person so people can play the instrument easily.•The part of the stand that is going to be inline with the users hip needs to be 1005mm or 1m and 5cm this is because this is the height there arm is going to be whilst they hit the instrument. •I am going to add a handle so that once the product is been dismantled the user can then carry it easily. The width of the handle at minimum has to 165mm so that the average man can get his hand through comfortably. (all of the anthropometric data is from the Body space book of anthropometry, ergonomics and the design of work)Dimensions – Well I am going to make the stand big enough to fit 3 of my clients gongs.•There are 3 gongs they are 28cm, 35cm and 36cm I will make the top bar wide enough so that you can use the stand for all of these gongs.•Car boot dimensions – with seats down the boot capacity is 2500 litres.Cost limitations – £50 – 60.Durability – My product will be used on a regular bases for rehearsals and performances it will need to withstand shocks and be easy to carry.•I will achieve this by making it easy to fold up therefore making it easy to transport and fit in cars.•It will be well designed so that the stand will be able to hold the gongs weight and absorb shocks when being used.•I will be applying varnish to my product to protect it from scratches as it will be used regularly. Specific aesthetics – My product will feature the bands logo and I will consider shape to make it more abstract while designing.•I will achieve the logo by using the laser cutter to raster an image onto my product. •I will use pro desktop to create my product so will consider interesting shapes when designing.Safety aspects – I will make sure it has been sanded well to make sure the user doesn't get any splinters.•I will use sand paper to achieve this.Impact on the environment - I intend to recycle any material I do not use so that others can use it.•I will be using very precise methods of production such as the CNC router and the 3D printer so there will be little waste. Time restrictions – Friday the 4th of April is when the manufacturing deadline is. •I will need to make sure I meet every deadline in order to have enough time to manufacture and have time for developing.Manufacturing – I intend to use machinery such as the CNC router to make my product.•I will be using the CNC as it is very accurate and allows me to use pro desktop to make an interesting and accurate design.•I will also be using the 3D printer to make connectors because my client has requested there shall be no bolts connecting the components together.

The stand will be used once a week so need to last for years.

This design was my first idea as I wanted to see what a basic stand would look like whilst still meeting the specification I then used this design to base my other ideas so that I could make more abstract designs. I have displayed a hasp and staple showing how it would fold up with out nuts and bolts which was in my specification. The product is in 3 pieces so you can take it apart and transport it easily. The stand is very stable as it has a sturdy base so that it can take the weight of the gong. My idea meets the specification of my client as it has no nuts or bolts used in the dismantlement, also as it is simple many personal things could be added on top of it for example graphics could be raster upon the stand if this should be something my client desires. I will be making this out of ply wood as I can apply a finish to it and I said in the safety aspects that it needs to not have any splinters. This design is good for the manufacturing aspect of my specification as I said I wanted to use the CNC or laser cutter as it will be very precise.

I think it is a bit to simple compared to my other designs but it can be added to, to make it personal to my client and his band. It fits the specification on a basic level as it is easy to dismantle and reassemble. My idea of using a hasp and staple I have decided is not the best idea as it does not look aesthetically pleasing I think I am going to got for some form of abs connector which would look a lot more professional.Client Feedback “I like the first one, and the way the top of each side folds back and that there are relatively few parts. I wonder if it's unnecessarily chunky, though?” In my drawings I had to stick to the isometric grid so the designs would be a lot slimmer when I actually make them . I will ensure that it is still sturdy when I make it slimmer.

Design idea 1

This design is a lot more abstract as it is in the shape of an „S‟ as this is the initial of the band so this is something that i think would represent his band well and that he would like, the only problem is that I haven't yet thought of a way to allow it to fold up but I will do this in development if I chose to use this design. I've have added a feature for the stick you hit the gong with so that makes it more of a complete and new idea as no other gong stand has this. This can be made out of wood such as ply which makes it affordable and I can also manufacture it easily and precisely, I can also apply a varnish to it which I said I would make sure I do as it cant have any splinters. It has been designed ergonomically as the stick hanger will be at a comfortable height for you to pick it up and I looked into the anthropometric data of the average hip height so it is comfortable to user for many people. At the moment the surface is plain and this can be edited as I may raster the band logo onto a part of the stand to make it personal to them. I am going to have to look into ways that I could possibly make it fold up I am thinking I can using the 3D printer to make a connector.

Design idea 2

Because I will be using wood for this and manufacturing with the CNC I wont leave much waste but any I do can be used by somebody else so this design has a good impact on the environment. I can make sure the size of the gong area is suitable to fit all the gongs in so that it fits many different sizes of gongs. Personally I like the look of this idea but I think if I were to use it, it would need a lot of development but I like the shape and handy features it has.Client Feedback“Would look spectacular and I appreciate the capital S for Skintight idea, but it seems like a lot of material to hold relatively small gongs” these ideas may not be good for the cost limitations as there is a lot of wasted material at the bottom as the top area would have to be large meaning the bottom has to be to making it rather large but I could do something in development to make this work.

Design idea 3I think this design is an improved version of the last on as I took inspiration in terms of shape as I stuck with the „S‟ shaped stand but this time added two ass I thought it would be a lot more supportive as it is going to need to absorb shock as its going to be moving a lot. I took the middle bar from my first design as I thought it was good as it will be able to slot it very easy and will dismantle well. I also displayed on the right hand side a way in which you could cut the „S‟ in half and attach it using an abs connector made by the 3D printer as this meets my specification as it is easy to assemble without using nuts and bolts. I've added to pieces of wood at the bottom as it gives it more stability as it needs to support the gong well. It has been designed using anthropometric data as I researched into the average hip height of people to make sure it would be comfortable no matter which member of the band is using it.

This design idea also has a plain surface area at the moment but I can also apply logos to this of the band which I said I would do in my specification. Because I think I will use ply wood to make this as it is good when manufacturing I can apply a varnish to it to make sure nobody gets splinters when using my product. This idea meets my specification very well as it is an abstract design that relates to my clients background and also can be assembled easily.Client Feedback“Would look spectacular and I appreciate the capital S for Skintight idea, but it seems like a lot of material to hold relatively small gongs” these ideas may not be good for the cost limitations as there is a lot of wasted material at the bottom as the top area would have to be large meaning the bottom has to be to making it rather large but I could do something in development to make this work.

Design idea 4I think this idea is a lot different to my others as it uses a completely different base the only problem with it is it has many pieces so will be using a lot of material as it will need to be quite tall. I think the design is aesthetically pleasing and is quite unique. I have met the specification as it has connectors allowing it to fold up as small as possible. It has very supportive hooks to ensure that the gongs are sturdy these will be made out of metal. The thing I would need to take in to consideration if I were to chose this design would be that the top bar needs to be able to disconnect as this would limit how small it could get. I think the base is also too large as it would cost a lot in material. It has a large area for the gong to be in so this means that you could fit various sized gongs on this stand. As it will be made out of wood any excess material I get rid of can be used by anybody else. It will be very sturdy as I will use a precise manufacture such as the CNC router so it will fit together very tight and support the instrument very well. The connectors will be made out of ABS using the 3D printer so will be very sturdy and will hold the stand together well.

It has a very strong base so it will be a very supportive product which fits the specification as I said it need to absorb shocks and withstand regular use. As it will be made out of wood I will make sure it is sanded well and I can also apply a varnish to it to make it safe for any user so they do not get splinters. It has a lot of free space on the base were I could possibly raster on images that allow it to be personal to my granddads band.Client feedback“This would only take one gong so a bit limiting that way” I think if I were to develop this idea using my clients feedback I would show him the dimensions as the area in which the gong is placed can be altered in size.

Design idea 5This design is one of my favourites as it the most aesthetically pleasing in my eyes and it is my clients favourite. I think it is quite imaginative but wont be too hard to make as it is a shape that can be made on pro desktop easily. It is the best in terms of design and function as it has few components which is something that I needed to factor in. The development I would need to do is that it needs some kind of way of folding up either a connector like the other designs or the hasp and staple idea like on my first idea. I have used orthographic drawing to show the anthropometric data I found out as it needs to be hip height so anyone in the band can play it comfortably. I used the same bar in this idea which is something my client likes as it is easy for assembly. It also has space for rasteringwhich would allow the product to look personal for my granddads band. As it is in two big pieces and no separate base it will be sturdy and will withstand regular use.

It can be manufactured using the CNC router and designed using pro desktop so it will be a very precise manufacture. I will make sure that the product is sanded well and as it will be made of wood I can have a varnish applied to it for protection as it will be being used a lot so this is a necessity. I have flexibility in what size I decide the top bar is extending the width and area of the gong which will allow it to hold various sized gongs. This design meets all aspects of my spec apart from being able to fold up small without using nuts or bolts so this is something I will do in development.Client feedback“really drawn to the zig-zag idea, but again it would need to be slimmed down quite a lot to make it light and portable. Is there any way this could come into not many pieces?”

Design idea 6This design is much different to the others and not my favourite as I don't like the width it posses as it would look out of scale when a metre tall and the width would be similar as you can see I've drawn it square. Also it doesn't meet the main aspect of my specification as it cannot fold up but this is something that I would need to consider. I took inspiration from existing products as there are several stands in this style but I believe they are not very tall. Making this full size out of ply wood also may exceed the cost limitations. It would be very sturdy as it is one shape all stuck together instead of removable components. The product has a thick and wide base which will ensure the gongs stability while being played. It will be made of ply wood as this can be sanded and varnish to meet the safety aspects of my specification as I need to ensure the user doesn't get any splinters. The hooks will be made of metal so they are strong and don't fall out whilst holding the gong. This product will be able to be manufactured using CAD and the CNC so will be precise and fast. It meets most aspects of the specification apart from its ability to reduce in size.

Client feedback“Number two looks really nice and I like the incomplete arch shape. Again, it's very chunky, and it can only take one gong” even though my client likes the shape it his not his favourite as it is chunky and he needs it to be lightweight.

Development 1 For my first model I made the shape of my product based on my initial idea. I understood from this that it would work as a whole stand but was still unable to think of a way in which I could make it fold up or be connected allowing it to come in smaller pieces allowing it to be transported easily so the next part I need to develop is a way in which it can be produced in various pieces and still stand up maybe using connectors like in some of my other ideas.

From my first model I looked at the shape of it and understood that there was an opportunity to join each corner in some way so that it would fold down as shown in this new model. I cut out some card pieces and placed split pins in the corners to do some testing and figure out what I needed to do next. From this testing I deduced that I needed a mechanism in each corner so that it locked in when stood up and when folded down. Here is were I looked at the two examples displayed here as the clothes airer is able to stand up on its own and fold up, but after analysing it I decided it wasn‟t going to work in my product as I would masts in support. The knife shows a mechanism which relies on a switch that allows the mechanism to move and therefore making the knife stay open or stay closed. It was clear that I was going to have to devise my own locking mechanism that would work in my product but first I needed to make some bigger sized pieces in order to work it out. I also looked at the mechanism with in some gates as the bolt can enter different placed but when you slide it out to open the gate the bolt doesn‟t come all the way out and this is a feature I would like in mine as my client might lose one of the bolts.

Development 2

As you can see and as I said I would I made some plain larger shapes and what this did was allow me to position them how I wanted and put markings where I wanted the wholes to go as I had to decide where the bolt of a locking mechanism was going to go in order for it to successfully work in the two settings. I transferred the engineering I had done on the card into pro desktop and made two pieces on the laser cutter so that once I made my mechanism I could test it on the card. Once these were made I started looking at how I was going to make my mechanism. Doing most of this helped develop my engineering skills as I was starting to understand more efficient ways to transfer the information I had found over to pro desktop which would finally allow me to solve the issue.

Development 3

Here you can see parts of my mechanism I made this using ply wood I used wooden rods to make the bolt. I placed a hollow metal rod inside the corner to allow it to move but also it is were the larger side of the wooden rod goes as this stops it from falling out and allows it to pivot from different locking positions.

We can see here that it locks in when in both positions allowing it to stay open and not collapse but also allowing it to fold up. This was a successful test as I now knew that it was possible for my idea to fold. I feel like this has effectively tested my practical skills and that I am going to be able to develop this mechanism further.

I then tested out the new mechanism on my card model to see if I had successfully placed the holes on the right angle but doing this test made me realise that I needed to rethink the size of my pieces and the position of my holes,

I also then made the same lock pieces out of ply wood using the laser cut but found that the wooden rods did not fit inside the wholes I had printed so they need to be refined.

Development 4

Here is an example of some of the engineering that I had to do in order for the holes to fit up so it could stand up and fold down. I had to re align a few wholes and I did this by measuring were I wanted the new hole and then transferring this information over to pro desktop. This has now enabled y pieces to all fit together when being used and also when being transported. This has developed my skills in engineering as I am now able to quickly process the new measurements and transfer it into pro desktop which solves the issue.

Development 5

Size 8.5

At the top you can see I started to decide what size rod I needed to suspend the gong. I chose an 8mm metal rod and then drilled various sized holes into a piece of wood to see what fitted. I did this because I could then figure out what size I needed my holes on my piece, the most suitable was 8.5.

I then decided to make a pro desktop design that also had a variety of holes on so that I could compare the sizes and how well they fitted in contrast to the drilled version. I then concluded that 8.5 was still the most suited. I then put the hole into the piece which will be holding the rod. I also had to work out the most suitable place to put the hole so that the gong is well balanced and doesn't make the stand tip over. Now I have done this I am ready to print out my five pieces then I will start developing the feet and hooks which will help balance the gong and suspend.

Development 6

Development 7

I needed to create some type of base in order to support the stand, I came up with this idea which I sketched first and measured what sizes it needed to be, it allows the main pieces to be slotted into so its simple but effective and doesn‟t take any struggle to set up.

Having made it I tested it and it works very effectively and allows the whole product to stand a lot more stable. It is also the right measurement in order to leave enough space for the gong.

I needed to find a way of making sure the pieces were joined and that the metal joints didn‟t fall out to keep the pieces as one. To solve this I have designed caps that hole them in place. I started with using callipers to measure the inside width of the metal rods, I then used this to make the cap which I sketched first before then drawing on pro desktop. After printing it out I tested it in one of my metal pieces. I saw that it was to loose and would just fall out so I increased it slightly on pro desktop then printed it out again to discover that it fitted fine and would serve the purpose it was meant to keeping all the pieces joined and still allowing them to pivot.

After cutting the suspension pole which would be hung between either side of the stand I needed some hooks that would hold the gong. I used pro desktop to create this using the measurements of the pole. I then printed this out on the 3d printer to see that it fitted perfectly first time. Also the clip is the same either side so the hook can be used either side.

After creating the hooks I then set up the product and identified an issue. This was that the pole could quite easily be removed and slide out of its position when up, so I needed to find away of putting something on it so that it stopped and stayed fixed in position. We looked at many things that could possibly stop it and the most suitable and effective way was to attach washers to the insides using araldite this would stop the pieces from sliding any further down the pole. I then needed something on the outsides to stop it from moving but it needed to be removable so that you could remove the pole when finished using the stand. I solved this issue by threading the ends of the pole so that nuts could be screwed on and keep it all in place these are then removed when dismantling and the placed back on the thread when the pole is out of the stand. Having the nuts placed back on the pole once dismantled allows them to have a place to stay and not get lost.

Development 8

I needed to find a way of storing the pegs that are used to set up the stand and keep it in place so I decided to create a box that would be attached to the base piece so that it was part of the product so you do not loose it. I developed this by creating the box pieces on pro desktop and then assembling them after printing them out using 6mm ply wood fitting with the rest of the wood. I assembled it using wood adhesive and elastic bands to keep it together, I also glued it to the main piece using the same wood adhesive. I then tested it out and all the pegs fit in it easily. I then had to create the lid so that it closed but stayed closed so the lid didn‟t fall of when travelling. I did this by using a catch so that the piece in the middle slots in and the main pieces covers the top and keeps it closed and looks professional.

I purchased some polyurethane varnish after doing my research and deciding that it would offer the best finish as it is spray on so is quick and easy to use it is also consistent and leaves not marks from things like a brush's I had to take this home to varnish as the fumes are dangerous. I did two coats on all pieces and used wire wool to remove the fibres between coats so that it was a smooth finish.

Development 9

After testing the box and having made sure that everything was okay I then had developed all my final pieces and needed to varnish all of them in order for the wood to be protected as a lot of people will be using it and it needs to be safe and not easy to damage.

Having spoken to my client and his band at the start I was aware that they would like the band logo rastered on to the final product so I prepared a jpeg to use for rastering. I then thought that it would be nice to have „pegs‟ rastered upon the box were they go as it just makes it clear. Ilooked around the internet for a font which was in keeping of the bands logo font which looks like an African style as this is were samba is often performed. I found this font which was also very similar and fitting.

Before rastering I had to set it to a rasteringsetting that I thought would be appropriate and seeing as the first test I did was very nice and I was very pleased with I decided to stick with it for both jobs. It was the default setting for 6mm ply wood.

After doing the testing of the band logo and deciding that the setting was good I then rastered on to my final piece. I then rastered straight onto the lid of the box as I was happy with the setting. As I was happy with how it looked I also rastered it onto the other side of the stand so you can see the bands logo from either side. I think that rastering on to my product was a successful development as it allows my clients product to have a personalised touch so that when doing performances audiences can see that they have there own branded equipment making them look a lot more professional.

Development 10 – rastering

This is a wood varnish which is to be painted on to wood and it will protect your wood from damage and effects of weather such as water, this is important to use a finish when using wood as if the wood gets wet it can warp and loose its shape. This varnish is available in school and also shops such as B&Q, you can use it in school as it does not give off any harmful fumes like the spray on varnishes do. The disadvantages of this is that you have to paint it on with a brush which is quite time consuming and isn't a consistent job, you could also mark the wood with paint brush marks. I think seeing as time may be an issue it would be a bad idea to use this as I want it to be done quickly and also it doesn‟t offer the better finish.

This is a polyurethane wood varnish that is spray on, it works the same as other varnishes as it protects the wood from general damage and weather damage. It is spray on which is good as you don‟t need to use a brush so it is a more consistent finish with no brush marks. The main advantage of this varnish is that it is far quicker than painting it on this is good for me as I have many pieces to varnish so this will take a lot less time. The only disadvantage of using polyurethane varnish is it lets of dangerous fumes so is not safe to use in school so will have to be done either outside or in a room with ventilation so the fumes don‟t get to other people. I think this is probably the most effective if I want a clear finish.

This is a wood stain which offers a slightly different finish to a varnish, this one in the photo is a deep mahogany stain which when applied to a wood such as ply which is a very light wood in colour will then take on the colour of mahogany which can look a lot more sophisticated and expensive when in fact its not. Depending in what you are trying to portray through you're product this can be a good idea as if you want to make it look a lot more professional and expensive then you can use a stain on a cheap wood to attract certain buyers. Places like Ikea use wood stains on there products applying it to wood such as MDF and ply wood to make it look expensive but in fact keeping their costs down and their buyers. I think the main disadvantage of this is that it does not protect the wood as it is used to improve the aesthetics of the product instead of the durability. This is probably not a good option for my product as my client expressed that he wanted the wood to have its natural colours and also that it need to be protected from various types of damage as he will be transporting it a lot.

In conclusion I have decided I will be using the polyurethane finish which I will purchase from B&Q and apply to my wood at home either in the garage or in the garden in order for no fumes to get to people. This will allow me to get it done quickly and I think that also it will offer a more consistent finish to my product leaving no marks. I will apply two coats to make sure that it is well protected, this will allow my product to protected from general damage and weather damage which will be beneficial to myclient when transporting the product on a regular basis.

Wood finishes

Flow diagram

Start

Locate all final pro desktop files.

Create a DXF file on pro desktop. Export on to memory stick.

Open 2d design and change base size to the size and depth of the timber.

Import DXF file from memory stick.

Check the pieces in the DXf are the correct ones

Yes

No

Position design were you want it to cut.

Click on CAD wizard and click soft woods in the machining materials.

Select outside offset in machining plans. Then select all the outside lines of your design.

Then use inside offset to select the inside lines.

Click check output to see if you're happy with how it will cut.

Once you're happy click post output.

Make sure the cutter is in position.

Make sure the extractors are turned on.

Tell the machine to begin the job.

Make sure its cutting out correct

Yes

No

Make sure the fan is turned off before

turning the machine off, once off remove the

piece of timber.

Remove pieces from wood using a blunt

tool, I used a steel rule.

Continue to next page

Align all holes to check pieces have been cut out

correct.

Flow diagram

Use a course sandpaper of grade 600 then a fine

sandpaper of 600 to make it smooth and ready to

work with.

Watch for splinters

Collect a hack saw and 8mm hollow metal rod. Make sure you carry the

saw sensibly holding it by the handle.

Cut the rod into 8 24mm pieces to fit inside the holes

connecting the wood pieces.

File down metal pieces so they are no longer sharp on the edge, then insert them

in to the wooden joints.Watch for sharp edges

Get a 6mm steel rod. Then cut them into

30mm long pegs to fit the smaller holes.

Now all pegs and joints are cut assemble the product to see if it stands up and all the

pegs fit. QC

Locate all pro desktop files for the 3D printer.

Make sure all files you want to print are open.

Go to file, export and then select stereo lithography file.

Then select binary and then export it onto a memory stick.

Open HP Designjetand import designs then press print.

Insert the tray into the 3d printer.

Press print on the 3D printer to begin the job.

Once finished remove tray and place in bath of

solution. Assemble the pieces onto main product to see if they fit.

Do they fit correctly and

hold the product together

successfully?

Check all pieces are

correct size.

No

Proceed to cut the main suspension pole out of 8mm

solid steel.

Yes

Check that the pole is the correct length and fits in the

allocated holes.QC

Using araldite glue metal washers on to the pole inside

of the wood pieces.

Continue to next page

Flow diagram

Then thread the ends off the pole on the outside of the wood, then making sure the nuts fit on properly.

Do an assembly to check that pole is correct and that the

caps and hooks work correctly.

Gather pro desktop files for pegs box.

Make sure they're all open then.

Got to File, Export then click DXF file.

Import files into blank engineering drawing.

Then export DXF file onto a memory stick making sure CAD R10 is selected when

exporting.

Open Corel Draw in laser cutter room and import DXF

file

Make sure the job size is the same as the piece of material.

Focus the laser cutter to your material then press print.

Make sure the extractors are turned on.

Apply wood adhesive to joints then hold together with elastic bands in order for the box to keep its shape whilst drying.

Then glue the two pieces for the lid together

Assemble box to make sure it works correctly

QC

Locate jpegs files ready for rastering.

Open files on Corel draw and position were you want to

raster

Select MDF ply- 6 on rastering settings

Then press print on the computer.

Check that rasteringcame out as you would

have like.

QC Re-assemble product and lay flat ready for

varnishing

Make sure garage door is open for ventilation

and that the inside door is closed so no fumes

escape indoors.

Use wire wool to remove fibres then give

it all a second coat.

Once dry and varnished fully do a full assembly

to make sure everything is working

as it should be.

QA

•Add the questionnaire results!!!!!!•Add a slide that shows the size of the car boot as this is key to your product!!!!!!•Show your experiments with rastering and justify the setting you decided to use.•Add a page of research into wood finishes and justify the one you will use.•Show your product fully assembled in Prodesktop album and orthographic drawing.•Create a flow diagram that sets out all the steps of manufacture, include images and print screens of the process. Also include any health and safety steps and quality control steps (these are usually in the form of questions in diamond shaped boxes.)•Plan a slide of testing with your client and the band.•Evaluate your design process, your manufacturing performance and the final product against the specification.