industrial design portfolio, daniel cornish

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DAN CORNISHINDUSTRIAL DESIGN

[email protected] 32 DANIEL CORNISH

4 - 17 18-35 36-55 56-67

MOJO CIRCULAR SAWWAVE SPEAKERITUS BARRIER SYSTEMLIQUID SOLDERING IRON

CONTENTS


MOJOCIRCULAR SAW

MOJO IS A COMPACT CIRCULAR SAW THAT WILL ENHANCE YOUR EXPERIENCE IN THE GARAGE OR WORK SITE


INSPIRATION

Deiter Rams Ten Principles of Good Design were used as inspiration for the form of this project.

Deiter Rams Design Principles

Good design is innovativeGood design makes a product usefulGood design is aestheticGood design helps a product be understoodGood design is unobtrusiveGood design is honestGood design is durableGood design is thorough down to the last detailGood design is concerned about the environment


RESEARCH

Traditional circular saws tend to have complex shapes that vary from product to product. These odd shapes are dictated by the placement of the dominating components, in particular, the motor and blade. Todays products arrange the motor on one side and the blade on the other. The weight of the motor is off center which can negatively affect handling. These problems present opportunities for improvements.

PERSONA

Mark spends a significant amount of time working on home improvement projects. He is currently in the market for a compact saw with a full size blade.


PROJECT STATEMENT

Current circular saws on the market are bulky and obtrusive. They are hard to store and are heavy to carry around. These types of saws are used for commercial applications, but also used by many DIY homeowners. The objective for the redesign is to design a product that is compact, eye catching, and still provides the correct amount of power to spin a full sized blade.

IDEATIO

N THROUGH SKETCHING


DIMENSIONS

9.8 in

6.8 in

4.6 in

4.3 in

1 in2 in

1.3 in

3 in

3 in

1.4 in

3 in

7 in4.5 in

.5 in

.8 in

3 in

.4 in

2 in

3.9 in4.5 in

1.8 in

.2 in6.2 in

2 in

1.5 in

3.3 in

2.8 in

.8 in

2 in

1.9 in

1.5 in

7.7 in

1.8 in

6 in

11 in

1.3 in


PANCAKE MOTOR

The key to the saws sleek design comes from the Launchpoint pancake motor which is used to power the saw blade. It is 6 inches in circumference and has a depth of 0.5 inches.


WAVEWIRELESS SPEAKER

WAVE REPRESENTS THE RELATIONSHIP BETWEEN FORM AND FUNCTION


INSPIRATION

With a wide range of different types of speakers specialized for all sorts of various environments, I decided to pick two sources of inspiration to drive my speaker design. The first was a modern decor, the second was water movement. I want to combine the idea of constant motion and modern aesthetics to produce a one of kind floor speaker.

PERSONA

Hans LankophAge: 33Occupation: ArchitectHans has just finished his houseboat and has been in the market for a set of floor speakers to finish off his home entertainment system. When designing custom homes, he loves to incorporate modern aesthetics and make use of exotic woods. He has carried this theme into his own home and is looking for a set of speakers that will stand out, not just for entertainment purposes, and as a stand alone art piece. His dream speaker would mesh with the house boats wood accenting and also be cohesive with its modern aesthetics.


PROJECT STATEMENT

Design a unique and eye catching floor speaker with the use of a complex design while leveraging the manufacturing processes and materials to create a one of a kind product. The speaker will be using the latest technology to power and transmit wireless music. The full process from ideation, low volume and high volume manufacturibility, cost analysis, to material exploration will be addressed.

IDEATIO

N THROUGH SKETCHING


WIRELESS POWER

Wave has a wireless power module that converts electromagnetic energy into the power needed for the internal components. This technology is patented by WiTricity. To the right is a schematic that depicts the OEM components and how they are connected.

PART MATERIAL, FABRICATION AND COSTS (LOW VOLUME)

Below is a graph depicting the cost and processes for the low volume design.

Side PanelsMaterial: GlassFabrication process: Water jetSingle unit cost (material + labor): $701

BaseMaterial: AluminumFabrication process: Sand castingMold fabrication cost: $46,589Mold cost allocation for 1000 units: $46.50 / unit

FaceMaterial: Black walnutFabrication process: Steam bending/CNCSingle unit cost (material + labor): $219

ElectronicsEstimated cost of electronics: $500 per unit

$Low volume production quantity: 1000 unitsLow volume product cost: $1,975 per unit


LOW VOLUME DESIGN


FACE The face is black walnut and has three slots. Rubber inserts fit into holes that fasten the face to the base. With this type of attachment the face can be easily removed for maintenance or cleaning.

SPEAKERS Wave is made up of three JBL speakers, a 5 inch tweeter, 6 inch mid-level, and a 8 inch sub woofer

RUBBER INSERTS Fasten face to the base

SIDE PANELS Two inch frosted glass, built in lip that slips into groove in base which provide structure. It is then permanently attached with adhesive.

SCREWS Stainless steel, used to hold speakers in place

LOGO The logo is machined aluminum with a black chrome finish and fixed to the face

BASE The base is made of aluminum and has a black chrome finish.


HIGH VOLUME MANUFACTURING

The prototype Wave design was adjusted to accommodate the constraints of the manufacturing processes needed to support high volume production. The challenge here was to optimize the design for high volume manufacturing without negatively impacting the form and aesthetics.

ElectronicsEstimated cost of production electronics: $350 per unit

PART MATERIAL, FABRICATION AND COSTS (HIGH VOLUME)

BaseMaterial: PlasticFabrication process: Injection moldingProduction mold fabrication cost: $247,000Mold cost allocation for 10,000 units: $0.25/unitSingle unit cost (material, labor & mold amortization): $0.55/unit

Side PanelsMaterial: PlasticFabrication process: Injection moldingProduction mold fabrication cost: $157,000Mold cost allocation for 1 million units: $0.16/unitSingle unit cost (material, labor & mold amortization): $0.55/unit

FaceMaterial: AluminumFabrication process: Die castingProduction mold fabrication cost: $190,006Mold cost allocation for 10,000 nits: $0.19/unitSingle unit cost (material, labor & mold amortization): $1.45/unit

PARTS MATERIAL, FABRICATION AND COSTS (HIGH VOLUME)

With the high volume design different manufacturing processes were utilized. The face of the speaker is made of aluminum and produced through die casting. The side inserts are made of acrylic and were CNC cut. The base is plastic and was produced through injection molding.

$Production quantity: 1,000,000Production build cost of goods): $420 per unit


FACE The aluminum face is die cast with the three extrudes molded in. It has holes to hold rubber inserts that fit into fastening holes on the base. With this type of attachment the face can be easily removed for maintenance or cleaning.

SPEAKERS Wave is made up of three JBL speakers, a 5 inch tweeter, 6 inch mid-level, and a 8 inch sub woofer

RUBBER INSERTS Fasten face to the baseSIDE PANELS Two inch acrylic with molded in lip that slips into groove in base which provide structure. It is then permanently attached with adhesive.

SCREWS Stainless steel, used to hold speakers in place

BASE Base is made of plastic. Molded into the base are insert holes for the speakers, also molded grooves for side panels and holes for the rubber inserts that hold the face in place. Plus it has molded in ribs for structure.

HIGH VOLUME DESIGN


ITUSBARRIER SYSTEM

ITUS PROVIDES COMFORT OUTSIDE THE HOME


CITY OF SAN JOSE

The city of San Jose, California is the third biggest city in the state and has a diverse environment of people, cultures and ethnicity. Over the last 60 years the rapid growth of technology and electronic industries has accelerated San Jose into an urbanized metropolitan area. With all this expansion certain communities have been left in the dust and have become almost derelict. Even though these parts of the city are run-down the residents remain proud and deserve a safe and pleasant place to live, but as of now these neighborhoods are breeding grounds for illegal dumping and crime.

Spartan Keyes Alleys Study San Jose State University URBP 232 Urban Design Studio0SUSTAINABILITY EXISITING CONDITIONS 200 400

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IDENTITY EXISTING CONDITIONS 1: PLACE-MAKING CHALLENGES

VACANT SPACES*

CAR CULTURE*

GRAFFITI & GRIME*

DUMPSTERS & GARBAGE*

HOMELESS ENCAMPMENT

BUSY AND DISCONNECTING STREETS

* larger symbols represent a greater intensity of this condition.

SJSU PLAYINGFIELDS

SPARTAN STADIUM

SJSU TENNIS COURTS

SHARKS ICE

SAN JOSE MUNICIPAL STADIUM

KELLEY PARK

HAPPY HOLLOW

THE CITADEL ART STUDIOS

ART ARKAPARTMENTS

BESTOR ART PARK

BILL WILSON TEEN

CENTER TINH XANGOC HOABUDDHIST

CONGREGATION

GARDNER HEALTH CENTER

VIETNAMESE SEVENTH DAY

ADVENTIST

SJSUFOUNDRY

SOFANEIGHBORHOODARTS DISTRICT

SPARTANKEYESDISTRICT

The Spartan Keyes neighborhood faces many place-making challenges. Trash, graffiti and vacant spaces deter people from enjoying or even using the alleys. Additionally, heavy traffic along 1st, 2nd, 3rd, 7th, 10th, 11th, and Keyes Streets divide the neighborhood. This division is compounded by the mismatching land uses that exists in certain areas, in particular the areas between 3rd Street and 5th Street. All of these are barriers to creating a cohesive identity within the community.

Spartan Keyes Alleys Study San Jose State University URBP 232 Urban Design Studio

0SUSTAINABILITY EXISITING CONDITIONS 200 400Logo Here

Legend

Fall 2012

Marth

a StEast Vi

rginia S

t

Marga

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Keyes S

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East Hu

mbolt

St

Bestor

St

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South 2nd Street

South 5th Street

South 7th Street

South 8th Street

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South 10th Street

South 11th Street

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South 12th Street

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IDENTITY EXISTING CONDITIONS 2: PLACE-MAKING ASSETS

PLAY*

ART & ART SPACES*

CRAFTS & WORKSHOPS*

SPIRITUAL PLACES

SJSU FOUNDRY

GATEWAY OPPORTUNITIES* larger symbols represent a greater intensity of this condition.

SJSU PLAYINGFIELDS

SPARTAN STADIUM

SJSU TENNIS COURTS

SHARKS ICE

SAN JOSE MUNICIPAL STADIUM

HAPPY HOLLOW

SOFANEIGHBORHOODARTS DISTRICT

THE CITADEL ART STUDIOS

BESTOR ART PARK

ART ARKAPARTMENTS

GARDNER HEALTH CENTER

TINH XA NGOC HOA BUDDHIST

CONGREGATION

BILL WILSON TEEN CENTER

VIETNAMESE SEVENTH DAY

ADVENTIST

SJSUFOUNDRY

KELLEY PARK

There is great potential to create a more cohesive identity within Spartan Keyes. The existence of recreational activities along with a strong presence of artists production spaces and galleries present the opportunity to brand the neighborhood as the Spartan Keyes Arts District. Connecting these activities to a descriptive district label helps cement visual arts as the definitive image of the Spartan Keyes neighborhood. Crafted by the community and embracing their lifestyle, a strong arts identity can be recognized by visitors and residents alike. This will increase neighborhood pride and unite the community.

SPARTANKEYESDISTRICT

PROJECT BRIEF

For this project we teamed up with urban planners and local community members from the Spartan Keyes Neighborhood. My team was given the task of improving the alleyways that are littered throughout the neighborhood. Through community outreach neighborhood residents identified numerous issues with the current use and condition of the alleyways. These issues included degraded pavement conditions, poor drainage, illegal dumping, graffiti, loitering and criminal activity. Our goal was to design improvements that would ultimately start a rejuvenation process that would spread throughout the entire community. As a group we decided to design products that would bring people out of their homes and into the alleys, under the assumption that if residents were actively using the alleyways this would, in turn, detour crime and other illegal activities.


After meeting with the community members we used our findings to create ideas for solutions that would address their needs and desires.

COMMUNITY DRIVEN DESIGN

We met regularly with the residents of the Spartan Keys neighborhood and we worked together to discuss ideas and get their insight into which direction we should follow.

Our team conducted surveys to gather information on residents wants and needs. We also asked questions about their perception of their neighborhood. We compiled the data to gain insight into possible design opportunities.


IDEATION THROUGH SKETCHING


PROTOTYPES

Final three directions: A. Wall Maze - an interactive fence, to promote walk-though traffic in the alley. B. Hide-Away Game Pit - a lockable horseshoe pit or bocce ball pit, with access granted to local residents. C. Retractable Net/Barrier - used to block off traffic or used as net for games. Designed to be tamper proof.

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C


PROCESS ASSEMBLY

For our final appearance model we used a 3D printer.

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The final product is ideal for bringing life back into the alleyways. Named after the God ofProtection, the ITUS is a retractable barrier that is used to block off sections of the alley or street toprovide a safe place for kids to play. It also can be used a net for games. What makes our productunique is that it can be attached to a young tree and as the tree grows the ITUS housing wouldslowly be engulfed by the tree. Over time the housing and tree would become one. We producedour model out of plastic, but we designed the housing to be fabricated out of recycled aluminumby a local foundry.


HANDLE IS ATTACHED TO BELT

HATCH OFFERS ACCESS TO INNER MECHANISM

TAMPER PROOF SCREWS

HANDLE HOOK

ITUSS HANDLE ATTACHMENT BRACKET

ITUS BARRIER SYSTEM

HOSE CLAMP INSERTS

BELT SCREWS - ATTACHES BELT TO HANDLEHOSE CLAMP INSERTS


The ITUS is attached to the tree using hose clamps. The removable hatch on the side provides access to tighten and loosen the clamps. The hatch also houses the inner components, which enable the barrier to extend and retract. The hatch is held in place with four specialized screws to prevent tampering.

The inner mechanism is spring loaded and is designed to retract the belt easily after use whilst keeping the belt from kinking. The belt is held in place by screws that attach it to the spring loaded column.

The section view to the left shows the inner spring that allows the barrier to retract with ease.


The belt attachment is designed to be simple yet effective. Square holes are constructed to stimulate tree growth over the bracket quickly. The belt handle is slid over the arm extension when the barrier is in use. The bracket is attached to the tree with hose clamps

The pictures to the right are a representation of the expected tree growth over a ten year period. As the tree grows it will slowly engulf the ITUS - trees grow around the path of least resistance.

TIGHTENING CLAMP SCREW DRIVER INSERT

This image depicts the belt fully extended. Twisting the belt helps promote visual recognition for drivers by breaking up the consistent shape. The reflective material gives added visual aid to incoming traffic. The belt is attached to the handle on the main housing and was designed so that it would not become engulfed by the tree. The belt handle is placed over the arm extension of the attachment bracket which is placed on the opposite side of the alley or street.


LIQUIDSOLDERING IRON

It feels like liquid in your hands


INSPIRATION

PERSONA

Charlie HemmingAge: 35RC Car Hobbyist

Charlie has been building and repairing his own remote controlled cars for the last decade. One of his most important tools is his soldering iron. He has multiple cars and switches out parts frequently. He currently uses a soldering station at home for all of his repairs, but he is in the market for a more portable soldering iron so he can make quick repairs at the race track. Hes hoping to find a soldering iron that can meet all of his specialized needs and expectations.


ERGONOMIC ANALYSIS

To design a product that conforms to the hand, research was completed to analysis different configurations. When working on small parts it takes high amount of precision to complete the task correctly so comfort and weight distribution over the hand is important to address.

TASK ANALYSIS

RC car hobbyist uses soldering irons for changing batteries, repairing cables, building and repairing circuit boards. With typical soldering irons the user will hold the iron in one hand and the solder in the other. They will melt the solder with the heating element of the soldering iron to solder components/wires together.


OPPORTUNITYErgonomic shapeThat promotes accurate work

PRECISIONIMPRECISENESS

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BULKY

MARKET RESEARCH

There are many different methods of powering a soldering iron, only a few of which offer portability, namely butane and battery. Battery power was selected for this design to avoid the inconvenience and costs associated with buying and stocking butane gas containers.

MARKET OPPORTUNITY

The market research exposed a design opportunity for a high precision, portable soldering iron.

IDEATIO

N THROUGH SKETCHING


The Liquid Soldering Iron uses a base station to charge its battery. The green LED in the tail of the iron indicatesa full charge. The base station is also a equipped with a sponge for cleaning the soldering tip.

LED CHARGE INDICATOR

ON/OFF

HEATING ELEMENT

The shape of Liquid is based around the ergonomics of the hand. The curves of the iron nestle into the hand comfortably. It is designed to be held like a pencil, allow-ing the user to work with a high degree of precision.

industrial design portfolio, daniel cornish

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