Freelance Industrial designer services

Console Design:

Developed for Cardiotech Australia this console part will provide a facelift to an existing vibrating fitness machine. A series of concepts sketches were developed and presented to the client before the final design was achieved. The new console makes use of membrane illuminated buttons arranged in a very smart, simple and clean fashion. The new product is now perceived as a high quality product developed for the hi-end market.

 

Bathroom design fittings:

A new set of bathroom fittings were designed in ceramic for the Australian market. The new set was designed with a family look and minimalist style in mind. This new set of bathroom fittings will be available for sale soon.

 

Design of a plastic compost bin

This product was designed to store organic waste in the kitchen and then emptied into a larger bin sitting outside the house. The design had to be attractive to encourage the user to have it in the kitchen and use it. The product can be hanged onto any doors in order to be stored inside the pantry. The lid has 2 opening stages with a stopper to avoid this part closing when the product was being emptied. The capacity and size were determined by the average waste produced by the household and optimized to fit into a standard chep pallet for distribution.

20L Jerry can design:

This product was developed with the aim of improving the ergonomics when pouring the contents (when the product is full) and to refresh the look of the old model. The new design incorporates a second handle for easy pouring and 2 side elements with panels that provide the feeling of robustness, while at the same time offering protection. These elements are enhanced by a coarse etching pattern, specifically developed for this product, which adds an appealing design detail. The panels and ribs reinforce and provide strength where the product needs it most. The two “X” shaped elements used on the original jerry cans were kept, with an updated style, for reinforcement and to assist during the production process.

 

Coffee maker design concepts:

2 concepts were developed of a new coffee maker with the aim of producing an attractive yet affordable product. Each concept was designed for 2 different markets (young and mature) making use of trendy colours and minimalist shapes.

 

Bike Rack for Bombardier Transportation

 Second place in the design contest “Bike Rack for trains” from Bombardier transportation (2002). The design and shape of this rack makes it easy for the cyclist to locate his bike in less than 4 seconds before the train moves again. The design is provided with 2 panels on the back for promotional material and is protected with plastic (nylon) where in contact with the bike. The materials used are stainless steel tube, aluminum fixtures, stainless steel sheet and extruded plastic.

 

44L cooler: Design for Manufacture and Assembly

This cooler was redesigned for Willow Ware Australia using the same liner, lid and handles of the old model. The brief consisted in providing a new look by modifying only just the jacket and handle assembly. The new model was designed in 2 versions: with moving handles and handles built into the jacket. To do this the blow moulding tool was developed using 2 moving inserts that can be replaced to mold the 2 different shapes. The old lid is attached to the product by using 2 clips built into the liner. This modification reduced the assembly of the handle from 3 parts to 2 without any operator supervision. The hinges used for the closing clips was tested thoroughly and designed to last more than 1,000,000 opening cycles.

 

Overmoulded handle dish brush

Developed for The Decor Corporation this project involved the use of overmolding technologies for plastics. The brief consisted in designing a very simple yet attractive dish brush using TPR and reducing the amount of plastic used without sacrificing the integrity and ergonomics of the product. A good example of the outcome from mixing good design and engineering design. There is a continuity in the design, lines and proportions used for the final shape. The handle is the only fixed part of the injection molding tool whereas the head and neck is an insert with different shapes for various brush models. The use of Moldflow was very helpful to determine if the 2 layers of plastic would be manufactured successfully. A Finite Element Analysis (FEA) is performed to determine the minimum thickness for the neck without compromising the strength of this area when the product was in use. The results were tested with several hand made prototypes and 1 FDM (rapid prototyping) model for the final design.

 

Kids furniture design:

In 2001 an amusement park for kids in Mexico City announced the design competition for an innovative kids furniture to be used as a table and as a bench table in this theme park. The product was designed with ergonomics for kids and with the idea of a fun, safe and easy to understand transformation using a simple locking mechanism. The design was was awarded with the first prize for functionality, innovation and aesthetics. An extensive research was carried out to select the right materials and processes for durability and look of this kids furniture. This design patented design is made of rotational moulded plastic (HDPE) and stainless steel tubes.

 

Design of a baby bathtub

A fresh and modern looking bathtub designed for newborns. The design incorporates storage areas for soaps and shampoo bottles as well as a soft cushion to gently support the baby. The design was awarded with the first prize for functionality, innovation and aesthetics. The product was presented in a variety of colours and textures. The design was tested using a functional prototype made of glass fibre which was also used in focus groups sessions, benchmarking and to be exhibited at the International toy fair in New York in 2001. The material and processes used are PP injection moulded.

 

Blow moulded plastic pavement sign

Designed to hold an advertisement panel in the windy conditions of Melbourne this product is made of blow moulded HDPE. The base and side columns can be filled with sand to prevent the product from being pushed by the wind. A set of concepts were developed to be manufactured using either rotational moulding or blow moulding processes to produce these hollow large parts.

 

New blow moulded ice pack design

Made of blow molded HDPE these bottles were designed to replace the old models. The design was based on a circular shape and makes use of coarse etching on the side panels to simulate a frosty - icy look when the product is cold. The new bottle design also addresses the issue presented with the old models where the cap could break easily if the product was dropped when frozen. The cap is an injected part which makes it very brittle when frozen due to the amount of stresses that the plastic was put through to inject it. Since the new body is blow moulded the stresses are lower and the impact resistant higher. With this in mind the cap is now protected in the new design by the 2 shoulders on the side of the neck of the bottle.

 

Design of a plastic pet food scoop

Companies spend large amounts of money in product returns and temporarily fixing product issues. By understanding the root causes of the problem and using the right problem solving tools the solution can sometimes be very simple and less expensive than these type of temporary fixes.

 

5L Fuel can concepts

A series of design concepts were presented for the new blow moulded 5L fuel can designed for Willow Ware Australia. The new cap and body concepts look more sporty, robust and modern than its predecessor.  The body incorporates sharp looking edges with enough draft and fillet size to be manufactured using the blow moulding process. The body incorporates panels with coarse etching and the tap design has a unique shape easy to mould using a conventional injection moulding tool (no inserts except for the thread).

 

Design of a new plastic rubbish bin

A new design makes use of a fulcrum mechanism that closes the flap automatically using the weight of the flap itself. The weight is located at the back of the flap in a circular shape that enhances the location of the logo and acts as a handle to remove the lid to empty the bin without touching the lid with your hands. Due to its “cute” look the concept was presented in various colours for kids (girls and boys)

 

Water tank design

With the dry conditions intensifying in Australia, the use of water tanks is very common in this country. This project consisted on the design of a water tank that could be manufactured in a blow moulding machine. The maximum capacity available for the new product was 170 L due to the size and capacity of the machine. The new design makes use of a standard grid to avoid dirt, leaves and rubbish getting into the tank. The side panels incorporate 2 wavy looking ribs to provide structure to the product when the tank is full of water.

 

3K and 1.5 K Pet food pourer design

Designed as a promotional product this pourer shares a family look with other products from the same family such as a lid and a pet food scoop. The use of mirror finish and etched surfaces enhance the features and branding on the product. The final design incorporates an air tight sealing lid and a sliding flap that allows the user to control the pouring volume. The body incorporates a small lip at the front to compensate the weight of the product when full and in use. Given that the lid and flap share the same colour, a family tool was designed to manufacture those parts. Some moldflow analyses were performed to balance the runner system and fill the 2 cavities (lid and flap) evenly.

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