During my final semester at the University of Delaware, I had the privilege to participate in a newly developed class designed to teach industrial design concepts to the mechanical engineering student body. Along with my Junior and Senior Design projects, it was a valuable experience to apply theory and solve problems in the real world.
Content List
Overview
The course, led by Dr. Jennifer Buckley and industrial designer Whitney Sample, taught us many basics of industrial design, such as:
- Levels of prototype fidelity and ways to utilize them to their fullest
- Approximating form with soft foams
- Iterating quickly through 3D prints
- Materials used in each level of prototype fidelity
- Foam core
- Woodworking and treatments
- 3D printed models
- Plastic molds
- Acrylics/Plexiglass
- How to operate tools used in prototyping
- Acrylic bender
- Dremel
- Vacuum mold
- 3D printers
- Safe use of blades
- Sewing machine
- Considerations for user-friendly design
- Incorporating affordances to guide new users
- Ergonomic grips for hand tools
- The importance of user-centered research
- Conducting qualitative research with end users
- Interpreting findings to determine areas of improvement
As we learned new prototyping techniques, we would be assigned prompts that mandated use of one or more techniques. These “Individual Skills Mastery” tasks were completed independently from all other students and instructors to ensure each student learned through working with their hands directly. For example, our first assignment was to create an all-in-one hardware package for homeowners using foam core and paper prototyping skills.
Concurrently with the skills workshops and individual assignments, students worked in small teams on semester-long design projects sponsored by Stanley Black & Decker. These projects focused on improving aspects of their Hand Tools and Storage retail products currently manufactured and sold. Our teams conducted qualitative research with end users of our chosen product, recording their responses and identifying problem points. Each member generated unique designs that aimed to resolve the identified issues, creating foam core models to iterate through different forms before moving to 3D printed functional prototypes. Throughout the four month long semester groups met virtually with engineers from Stanley Black & Decker to share progress and solicit feedback and suggestions.
The project culminated at the Engineering Design Showcase, where each group presented their final findings and path forward to representatives of Stanley Black & Decker and attendees who agreed to a non-disclosure waiver. This project was subject to an NDA and thus I am unable to share specific details about my work. To summarize briefly, I created several CAD parts and assembly files incorporating stock fasteners and other hardware, as well as conducted analyses using SolidWorks motion study and created a Python program to process the output data into graphics. I thoroughly enjoyed the project from start to finish and I view it as the reason I seek a career in product design for retail products!
All-in-One Hardware Packaging
The course’s first project focused on creating an all-in-one hardware package for completing a household task. Using foam core and paper techniques, we were to produce a full scale package that properly contained all relevant hardware.
The household task I decided on was painting a wall or room. My packaging contained everything required (with the exception of paint), including:
- Tarp
- Sheets of sandpaper
- Angled and flat brushes
- Paint roller with spare roll
- Tub of spackle
- Putty knife
- Painter’s tape
- Stack of five paint trays
After creating concept sketches and getting my idea approved, I created a foam core prototype using craft knives, white artist tape, and hot glue. The kit was about the size of a paper ream box, and had three layers to store all hardware.
Ergonomic Grip for Hand Tool
The second project focused on redesigning a common hand tool to have a more ergonomic grip . Using structural foam, wood, adhesives, painting and finishing techniques, we were to remove or adapt the grips of real tools to improve their ergonomics.
The tool I focused on improving the grip for was the can opener. The way in which I aimed to improve the design of its grip was to add concavities for a user’s left hand to a wooden handle.
After creating concept sketches and getting my idea approved, I created a wooden prototype using a handheld Dremel, hand files, and coats of polyurethane as a sealant. I then removed the handles from the can opener, replacing them with my wooden prototype.
Comfortable Personal Protective Equipment
The third project focused on recreating a piece of personal protective equipment (PPE) so that it is more comfortable and ergonomic. Using casting, lay-up, acrylic bending, plastic forming, and sewing, we were to produce a wearable product that performed its protective duties while being comfortable and easy to move in.
The piece of protective equipment I focused on improving was lab coats, particularly their interaction with disposable gloves. The way in which I aimed to improve the design was to create elastic cuffs usable with any coat to protect the wearer’s wrist and forearm from hazards.
After creating concept sketches and getting my idea approved, I created a fabric prototype using a sewing machine and thread. The final product had two elastic rings to ensure a complete fit, and tapered to a larger diameter towards the user’s elbow. It was worn with a glove and my personal lab coat to confirm its functionality in sealing the glove/sleeve interface.
