AUG 2021 - Ongoing | Senior Product Designer
Challenge. To design a working physical prototype from 'napkin sketches'. Although this was a variation on my normal role working on digital projects, the design process didn't change as I collaborated with my client using a Design Thinking framework to understand the problem and quickly iterate through product design concepts and generate a physical prototype to be tested for a variety of airflow, rpm and current output metrics.
I was required to adapt my approach for this project as a product designer. The was no UCD, user research or Agile processes, just pure, unadulterated 3D CAD modeling and prototyping using 3D printers, CNC machines and some fiberglass molds. The creative process was consistent with previous projects, as we defined a problem, identified the perfect customer and ideated our way through a variety of MVP candidates and created working prototypes and the assets needed for manufacturing.
Expanding on my 3D modeling experience and furniture building hobby, I approached the challenge using a lean framework to design and build some pretty cool working prototypes that exceeded the client's expectations and would position him to disrupt the trucking industry by solving new idle restrictions and improve fuel consumption by 6%. Starting with rough sketches, we would iterate untill we reached an MVP candidate that would generate enough wattage to charge a bank of batteries used to power secondary systems.
Product Design. Using Fusion360 to develop parametric 3D models we created a series of size and feature options to validate and refine the designs for a modular product offering.
Prototyping. Physical products need prototypes too, and this very iterative exercise would be tested with mathematic precision in order to generate the airflow and amperage needed to charge batteries. This often necessitated tweaks to our designs to produce the most volume from a turbine we could 3D print.
Several working prototypes that would be tested to measure output for an air powered option for charging battery banks. A set of detailed plans, 3D models and g-code to be used in continued manufacturing of the product. Considerable research was conducted into manufacturing processes, 3D printing, mold making and CAM.
We designed and built multiple physical prototypes from 3D CAD models printed on a 3D printer, and built fiberglass molds created on a CNC machine. We explored a number of best practices and manufacturing processes to scale production for future demand using design assets created during this project.
