Sustainable design project to reinvent the toothbrush.
Millions of disposable toothbrushes are land-filled every year, they cannot be recycled easily, and the lifespan of the materials far exceeds the lifespan of the product.
A holistic analysis of the current cradle to grave model was used to rethink the way we produce and use personal care products.
The main principles of sustainability used in Tooth+ are dematerialisation, increasing the longevity of product life, utilising waste streams, circularity of material flow, minimising the impact of material and manufacturing.
Toothbrushes are almost always replaced because of worn bristles, yet the handles are often left in excellent quality, yet are needlessly thrown away.
The basis of Tooth+ is to up-cycle the handle by removing the existing head, and retrofitting it with an adapter. Transforming what was once destined for landfill, into a reusable toothbrush with replaceable heads.
For early production, the adapter would be made from WillowFlex, a compostable, flexible bioplastic made from corn starch. The later stages of production would hopefully see the creation of decentralised, local recycling facilities that would be able to reclaim Polypropylene (PP) from discarded toothbrush handles. More R&D is required, but early experiments with PP from ground up toothbrush handles are shown.
Outdoor living design challenge.
-Metal Working skills
Fires are great for camping, festivals or garden parties. Unfortunately they can scorch the ground underneath, killing grass and making a pretty unpleasant sight.
FireBowl is a simple solution for safely and respectfully making fire on the go.
This project taught me a lot about working with metal as well prototyping processes. I started with paper then cardboard and wooden model, adapting and pushing the design toward the final product you can see today.
The off the floor design prevents the ground beneath from being burnt. Firebowl uses a stable leg structure to prevent the fire from tipping, even when heavily laden with wood. The design allows good ventilated air flow that makes fire starting a breeze. The interesting geometry makes it an appropriate permanent feature in a garden. Yet it's flatpack design means you can take it away camping or to a festival.
FireBowl is made from stainless steel and finished with heat resistant black paint.
The materials were chosen though experimentation and research. After initial selection I tested materials by heating samples and checking factors such as damage and discoloring.
My original design used only three shafts, acting as the hinge joints and as the legs. However, though early prototypes I realized that the parts collided in the center. This led to the use of two part shafts and a central connector piece. Prototyping saved me a lot of time and effort in the later stages of development
Making the FireBowl taught me some metal manufacturing techniques and equipment. To cut the sheet metal a stamp was used for the straight and a plasma cutter for the curved edges. Oxyacetylene brazing was used to attach the hinge tubes to the sheet metal.
Although the build of the FireBowl prototype was labour intensive, the manufacturing process could be streamlined for mass production. For instance reducing the amount of welding by stamping and rolling sheet metal. Tap and die was used to create thread on the tubes and shafts, allowing the whole thing to be disassembled.
Other adaptations could be made to reduce weight, such as perforating the sheet metal and using hollow tubes instead of solid shafts. However FireBowl is intended for a long life which is reflected in the quality of materials.
Vehicle interior design and build project.
Harmonauto is a concept design for a two person autonomous vehicle for use in the crowded city of Shanghai. Shanghai faces issues of pollution and overcrowding as well as accommodating a wealthy international business sector. Harmonauto is designed with a large focus on anthropometry, ergonomics and user experience to make the vehicle as accessible as possible.
Design of lung measuring device for low income countries.
-Data Readings and Analysis
Amun is a low cost spirometer, used to accurately measure tidal breath volume and residual lung volume.
The focus of this project was in human factors, ergonomics, experience design and hygiene as well as developing accurate and reliable technology.
Mecahnical Design of a small locomotive robot.
-3D Modelling and Assembly
Wheg – refers to a wheel-leg; a wheel with leg like appendages instead of a circular face.
Mini-Wheg – refers to the robot device that utilises Whegs.
A 3D modelling design project, to produce a small locomotive bio-inspired robot. Design was based on the Mini-Wheg robot series, adapted to incorporate a tail that aids obstacle climbing and stability. The design achieves major outcomes of weighing 204 g, overcoming obstacles 55 mm high, moving at 0.5 ms-1, total cost of materials below 100 GBP. Total length (including tail) is 202 mm, width 126 mm (including Whegs) and height80 mm. Engineering analysis of bending in the shaft allowed effective design for weight and strength. The design incorporates a rack and pinion Ackerman steering system with a Rzeppa style universal joint. The device is powered by a 7.4 V hobby motor and power transmitted through a DC motor coupled to front and rear shafts via a pulley and belt system.
Mechatronic Design Project
Gizmo was a fun design project creating the organic sounds of the rain-forest with mechanisms, electronic components and a control system. The contraption uses rain-sticks controlled by a motorized Geneva mechanism, two bird whistles powered by crank-slider bellows and a thunder-drum.
The full working mechanized rain-forest sound machine
Bicycle frame design project.
-CAD 3D Modelling
Finite Element Analysis (FEA) was used to inform and test the design of a unisex three person tandem bicycle frame. The bicycle frame had to satisfy weight, stress, fatigue and oscillatory requirements.
The true displacement in the frame when loads are applied
The stress in the frame when loads are applied
1st Harmonic Vibration
The 1st harmonic oscillation at 58 Hz
2nd Harmonic Vibration
The 2nd Harmonic oscillation at 60 Hz
Design and build of two bespoke outdoor planters made from decking boards.
The planters were designed carefully with the purpose in mind. The sizing was selected to fit seamlessly in the required space, but also accommodating the dimensions for healthy plant growth. Decking was chosen for it's weather resistant pre-treatment and matching aesthetic. The design is raised off the ground to allow air flow and avoid damp. The inside is lined and filled with soil and pebbles to allow good drainage.