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RM: Innovation for, through, and of
ExtremesBy Jason Jones & David I. Wimpenny
De Montfort University
Innov_ex 09 9 May 2009
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RM: Innovation
J. Jones Innovex 09 9 May 2009
through,for,
Extremes& of
RM: Innovation
J. Jones Innovex 09 9 May 2009
through,
Extremes
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LSLighting + Sand =
Fulgurite (fulgurite.com)
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LSLighting + Sand =
+ Metal Powder + Plastic
Powder
Laser
Laser Sintering (LS)
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Laser Sintering (LS or SLS)
3D Systems EOS
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SLA
Stereo Lithography
Apparatus(SLA)
Sap Left for Ages
Stereolithography (SLA)
3D Systems
Terminology
LSSLAFDM
3DP
SLMJetting
USCLENSSLS
RM: Innovation
J. Jones Innovex 09 9 May 2009
through,for,
Extremes& of
RM: Innovation
J. Jones Innovex 09 9 May 2009
for,
Extremes& of
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rip_(
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• Pressure a helmet exerts on the head
Correct helmet Small helmet Customized helmet
What is Custom-Fit?
is:
• A Paradigm where• Digital Manufacturing is• Driven by Customer Data in order to• Produce Customised Products for their Body
What are you going to change?
Customised liner
Padding
EPS
How to do it?
1. Start with a 3D helmet model in the computer
2. Scan the head
3. Morph the helmet design to fit the head
4. Make the helmet
Sou
rce
: C
ust
om
-fit.
org
3D scanning
Automated design
07/04/2023
Result
07/04/2023
Growing Wish List
AIR
(Results: failure. HIC = 2460; peak = 280G)
The Next Generation
The customer is always right.
Sou
rce
: D
uca
ti.co
m/ L
ou
ghb
oro
ugh
Un
ive
rsity
Customer feedback
92% of the motorcyclists
surveyed feel discomfort from the seat when travelling long distances
Sou
rce
: D
uca
ti.co
m/ L
ou
ghb
oro
ugh
Un
ive
rsity
• Results from on line survey: motorcycle seats
Do motorcyclists want customised seats?
Yes, 81.10%
No, 18.90%
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
80.0%
90.0%
Customised Seats according to BodyGeometry
Customer feedback
Sou
rce
: D
uca
ti.co
m/ L
ou
ghb
oro
ugh
Un
ive
rsity
• Results from on line survey: motorcycle seats
Customer feedback
Yes, 78.9%
No, 21.1%
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
80.0%
Willingness to Pay for Customised Seats
up to €250, 66%
<€500, 31.30% >€500,
2.70%
0%
10%
20%
30%
40%
50%
60%
70%
Willingness to Pay
Willingness to Pay and Wait
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ti.co
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ou
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Un
ive
rsity
What part(s) to change?
StabilityPad (inside)
Comfort
Aesthetics
Cover (sky)
Bottom
Cover (sky)
How to meet customer need?
• What bike part(s) to change?– The Seat
• How to drive the changes?
• What changes to make?
Sou
rce
: D
uca
ti.co
m
How to drive the changes?
• Unsuccessful attempts: Scanning Measuring
Sou
rce
: H
um
an
-so
lutio
ns.
com
(fa
r le
ft)
• Success: Empirical data from Pressure Map
How to drive the changes?
How to drive the changes?
• What about subjective data (your feelings)?
Sou
rce
: IB
V
Emperical Data (mm Hg)
Subjective Data (Feelings)+ Hybrid Data
(Comfort Map)=
How to drive the changes?
How to drive the changes?
How to drive the changes?
How to drive the changes?
How to drive the changes?
Zone 3
Zone 2Zone 1
How to meet customer need?
• What part(s) to change?– The Seat
• How to drive the changes?– Empirical + Subjective Data
• What changes to make?
Sou
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: D
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ti.co
m
What changes to make?
• Laboratory Stiffness testing:– Establish the dynamic performance of the
standard seat material (benchmark)– Explore the performance of alternative
materials
What changes to make?
• Create a “pseudo pocket sprung” seat– Using CAD & Computer Analysis (FEA) to – Hollow out the inside of the seat– Use the force vs. displacement curves from the
laboratory stiffness tests to design individual “spring” like structures.
What changes to make?
• Using CAD & Computer Analysis (FEA):– Make an array of the “spring” like structures
– Insert them into the seat according to…
What changes to make?
• …the customer defined Comfort Zones with the customer specified stiffness
What changes to make?
• Customised Seat making application
• Customised Seat making application
How to meet customer need?
• What bike part(s) to change?– The Seat
• How to drive the changes?– Empirical + Subjective Data
• What changes to make?– Graded stiffness
Sou
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: D
uca
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The virtual result
The virtual result
The virtual result
Digital fabrication
• Validated design using: Laser Sintering
3D Systems EOS
The result
Ducati seat
Top side Under side
Learning Outcomes
• Is the right material available?
• How we will collect the data (3D scanner)?
• What regulations might be barriers (CE, UL)?
• Will the market pay for the added value?
RM: Innovation
J. Jones Innovex 09 9 May 2009
through,for,
Extremes& of