The n580 is a total navigation sensor package for UAV’s, Autonomous vehicles, sensitive camera targeting systems, robotic manufacturing equipment, etc.. It’s a combination of accelerometers and gyroscopes that tell an object how it is oriented in space and its rate of acceleration. That information is combined with position data from a Global Navigation Satellite system and corrected for changes in nearby magnetic fields.
This is my ideal concept for the n580. It combines key usability considerations with an aesthetic that exemplifies Honeywell’s heritage of ruggedness. The finish is a thick black anodization layer for improved scratch resistance. The reliefs on the sides of the unit are for weight removal, and they are interrupted by the axis indicators. On other products axis indicators are a two-dimensional graphic that describes an IMU’s orientation with the x, y, z axis. By machining the axis in all three dimension my proposed indicators are a truer representation of how the IMU understands its position.. Bosses that house the screws responsible for connecting the clamshell, are separated from the feet for a clean and simple look. The feet are spaced in a square pattern, meaning that the n580 can be mounted in 90 degree rotations allowing greater integration flexibility.
My aesthetic principles were based on the value proposition of Honeywell’s military IMUs. Honeywell has a reputation in the industry for creating the most reliable and environmentally robust designs. The earliest prototypes had long sweeping curves, undercuts, and gentle geometry that didn’t fit with the value proposition.
Looking to remedy this I first had to simplify the exterior of the housing. The 3D print was one of the first designs and was driven purely by the positioning of the internal components. By understanding the assembly I proposed “flipping” the housing upside down which freed the top surface from hardware and combined the mounting feet with the bosses for closing the clamshell. This gave us a clean surface on the top of the unit to display our brand and allowed us to place a tamper proof seal over the screw-heads on the bottom.
The leftmost design was the initial n580 engineering model. Hexavalent chromate coated, with a blue engineering label, irregular surfacing, exposed hardware on top, and a rectangular mounting pattern on the bottom. On the opposite end is my vision concept that i pushed the engineering team towards. And throughout the our process we made a series of compromises that led us to the design in the middle. A highly functional, affordable, lightweight, waterproof (IP68), and brand sensitive design. We greatly simplified the shape of the design, and made conscious decisions to improve the user experience and the brand.
In the first release of the n580 we had a limited understanding of our future customers. As we observe how our products are being used, we continue to develop new ideas that improve our offering. Observing that most of the time the n580 will be enclosed in a dark environment amid other sensors and electronics, the team had the idea of incorporating lights into the device to serve as a verification that the n580 is functioning. I designed the position of the lights so they could extend into the chamfer which makes them visible even if the unit is mounted above eye level. We are also exploring methods of simplifying the manufacturing process. Currently we laser etch the anodization layer off areas inside the housing in the event of poor masking. At the same time we can laser etch the markings for the interface and lights. Because laser etching is a permanent process I believe it more clearly reinforces Honeywell’s reputation as a manufacturer of long lasting products.
In order to offer a competitive avionics suite, Honeywell proposed to update their touchscreen controller for the Epic 2.0 Avionics System. However, when the first designs of the new TSC where shared with Honeywell’s leadership team the concern was that the design looked outdated and plain. I was brought in to update the styling within 3 weeks, and i expanded my role to include solutions for additional function.
The touchscreen controller is the primary interface for data entry, flight plan modification, and communication with ATC. The entire flight deck can be controlled with this single device. The first image is the original engineering design and the flight deck it is designed for.
Honeywell leadership described their vision for the new TSC as a contemporary style but not so modern that it makes the surrounding components look outdated. To better understand their philosophy I created an inspirational design to have a conversation about what i thought contemporary styling would mean (top left). It includes, edge to edge glass, simplified physical controls, subtle branding, and hidden mounting hardware.
One of the most glaring issues was the antenna pocket machined into the top right of the unit and filled to the surface with an epoxy. An unprofessional look at best. The concept to the bottom left is a plastic part that snaps over the antenna hole and the top fasteners. This would work for covering the antenna hole but covering the fasteners would slightly exceed the footprint and risk not fitting in the cockpit.I conceded that i could not cover the fastener and decreased the width of the part. I also changed the surface of the part to a rubberized material (santoprene) that helps with gripping the top of the unit. I brought this concept to our human factors group and they agreed that a material with increased friction can improve hand stabilization, and that with the increased use of touchscreens in the cockpit, it has become necessary to provide features aimed to improve the accuracy of touch interactions in turbulence. At the same time this was also a prime location to represent our brand and by debossing it in the santoprene it was subtle enough avoid offending the aircraft OEMs.
The relationship between the knobs, buttons, and lights at the bottom of the unit needed to be unified. The engineering model did not attempt to resolve these elements, instead they were treated as isolated components. I focused in on this area in the final design.
The final design surrounds these controls with a unifying machined feature that rises from the aluminum bezel. The render to the right is an early version that raises the knobs and buttons above the bezel surface. This serves a dual purpose in visually connecting the knobs and buttons together and protects the buttons from being kicked as pilots enter their seat. The base of the knob is a texture-less skirt hidden by the surrounding bezel.
The buttons were based on cues from the original system, and although the interface is almost entirely touch based, which requires sight to interact, pilots prefer a few blind commands that require the tactile feel of buttons. The white stripe down the center of the button transitions into the thin machined stripe as it moves towards the touchscreen and relates the buttons to the interface controls immediately above them. The machined feature serves the same purpose as the original hardware’s painted white stripe, but it does so in a more refined manner.
An air separation module has a simple, yet extremely critical job- it keeps fuel tanks from exploding in flight. It takes bleed air from the engines and separates the oxygen from the nitrogen. The oxygen is waste and the nitrogen is sent to the fuel tanks to eliminate the chances of a fuel tank explosion. Without an air separation module the fuel tank would fill with explosive gas vapors as the engine’s aircraft burned more and more liquid fuel. An air separation module replaces those dangerous fuel vapors with non-explosive nitrogen gas passively separated out of the air.
In the past Honeywell acted as the middle man, selling air separation modules designed and manufactured by various suppliers to the OEMs. This product was Honeywell’s first originally designed air separation module, and my task was to help differentiate it from the rest of the aftermarket.
It can take 6-12 hours to replace an air separation module. Not a quick job, but a confirmed pain-point by the airlines. Using the aircraft maintenance manual I illustrated the installation and removal process of an ASM on a Boeing 737, then confirmed it with our engineers and business team. The most important finding was that ASM’s are not shipped with the insulation blanket, brackets, air filters, or any of the necessary peripheries. In fact, most of the time spent during the installation process is from carefully cutting the kapton tape that covers the old insulation blanket in a manner so that it can be re-used for the new air separation module.
Despite the variety of companies manufacturing ASMs, they are visually indistinguishable from one another. There is a standard yellow brown flame retardant blanket covering an aluminum shell. This look is unacceptable for our ASM since we are the only company looking at the air separation module as a holistic offering. Not only concerned with the products longevity or performance, but also the process of removing, replacing and installing. I wanted to take advantage of this difference and tie that back to Honeywell by branding the exterior of the product. The very first concepts were focused on changing the color of the blanket to a Honeywell brand color and attaching a Velcro seam to eliminate the excessive use of kapton tape. However due to the blanket supplier’s limitations, dying the foam a different color was not possible, and adding fasteners to penetrate the blanket would crush and rip the open-cells of the foam.
We solicited help from a material engineering specialist to find a material for an outer “sleeve” that could withstand the extreme temperature range (-70C to 50C), have enough elasticity to fit over the green brackets, and would not degrade if sprayed by the occasional jet fuel. The only material suitable for the job was a PTFE (Teflon) coated fabric. Unfortunately this material could not be printed on due to it’s unique non-stick properties, so I proposed an aluminum nameplate that could be attached to the sleeve with rivets. It provides a simple and elegant branding solution and is oriented so it can be seen once the ram air access panel is opened. The sleeve is held together using lock-wire and wrapped around capstans for a positive locking system.
I also re-designed the product label to read more clearly in low-light situations by increasing the font size, inverting the font color and background color, and clearly organizing important information for the technician such as manufacturing date, serial number, and part number.
Working with 3-D scan and 3-D print technology I realized there are many opportunities of marrying these technologies to produce the next generation of sport's equipment. This product is just one of many to come under the HawkTeck brand.
HawkTeck is a premium sports equipment brand that designs products for high-performance athletes. Their products are quick, lightweight, and aggressively styled. HawkTeck's first product is a custom 3-D printed soccer shinguard with sensor technology. The form is inspired by bird's bones and their lightweight characteristics. Bird bones form micro-trusses that make most of the bone hollow, as opposed to solid like in most animals. This reduction in weight is one of the many advantages that allow them to fly. The form of this shinguard utilizes trusses in the non-protective part of the shinguard to reduce weight and increase flexibility.
The process of creating a pair of these shinguards starts from 3-D scanning a player's leg and taking that scan into a CAD program. From the 3-D scan the shinguard can be custom designed to perfectly fit the player's leg. 3-D printing the entire shinguard ensures that it's organic form can be created with high precision. The shinguard also houses a gps module and an accelerometer to give the player an interactive replay of their past games. This system records metrics such as a detailed position density map, highest vertical leap, top speed, total miles ran and the location and speed of a player’s shots. This information is displayed through an application on the player's smart phone after connecting the shinguard and phone. The system works even better if more players on the team are also using HawkTeck's shinguard. This allows the players to see the relationship between their positions, how they are using the field throughout the match, and where they are taking their shots from. HawkTeck's shinguard provides a superior fit combined with technology so the players can learn more from their game, and design the attack.
Spark Awards Finalist 2015
Ignite is the first product under the Cro-Magnon Survival brand. The brand speaks to the freedom and the sense of adventure that lives in everyone. No one should be afraid to express these qualities, instead they should be encouraged. The world is your playground, so go explore it. And know that if you do find yourself in a sticky situation then Ignite is your number one survival tool, because with it you have the ability to create fire in any environment.
Ignite holds six pieces of ferrocerium, also known as “flint”. The same material that is found in your lighter. Ferrocerium sparks whenever it is struck against something that has a rough texture and is harder than itself. This means that Ignite can create fires on almost any rock. For best results, slowly scrape some ferrocerium onto the striking surface, and then ignite using a hard, fast strike. It is also recommended that you use kindling to help start your fires easier. A dab of vasoline with some cotton works especially well. Ignite will last for up to 200 strikes.
What happens to your umbrella when you’re done using it? You close it, you may wrap it up with its velcro strap, and then you tuck it away in your bag or place it on the floor. All the while you are getting your hands and all other belongings wet. An unpleasant experience on a cold day and a serious hazard to all of your modern day electronics. An umbrella protects you from the rain while you're outside, but fails when you go inside. How can this problem be reversed?
So how is this umbrella different? The Bloombrella uses a two-part rib that folds the canopy into the internal of the structure, so you never touch a single drop of water during use or storage.
The final prototype uses 3-D printed ABS rods and housings. Ideally the final product would still use plastic housings but the rods would be made of fiberglass, which is resistant to wear and strong enough to withstand flexing in high winds. The nylon canopy is made of two pieces to allow wind to pass through it. This gives the user more control in the wind and makes the Bloombrella resistant to inversion. The handle is made of mahogany for a premium look and is lengthened to provide a more comfortable grip.
TipcuP is inspired by the idea of the perfect morning. One of comfort and serenity. Much unlike the average morning that most of us experience, instead we are pressed for time and robbed of our mornings by our busy lives.
TipcuP is unlike any other drinking experience. It forces the user to take 30 minutes to drink their cup of tea or coffee. One has to prepare each sip. The schematic below explains how one uses TipcuP. Separate the bottom half from the top half. Pour your drink of choice in the bottom half and fit the top half back on. Tilt TipcuP towards the "hood" so that liquid flows from the bottom half to the top half. Tilt back when your finished pouring and wait for the liquid to cool before tilting the opposite way and enjoying your drink.
Design Brief: Design a chair for a specific task using only one piece of 8' x 4' plywood. No fasteners of any kind. Only wood joints can be used.
I designed a reading chair for the mornings and evenings. A chair that one would sit on to read the morning paper before going out into the day, or to read a novel at night before bed.
Kerf is the width between two teeth of a saw blade, and is also known as a method by which one can bend plywood. Cutting through most of the plys weakend the plywood so that it can be bent agianst a jig. Two pieces were kerfed and then laminated together to strengthen the seat pan. Perfecting the technique took many tests as the the depth and spacing of the cuts determined how well the plywood could be bent. Too deep and close together the plywood would snap under pressure. Too shallow and far apart the plywood would not accept the curve and break when clamped to the jig.
Donetsk is based on the Ukraine-Russia Crisis that has claimed 5,400 lives so far....
It's about the unnecessary damage and destruction that the Ukraine-Russia situation has caused. Over 150 red oak pieces were used to build this chair to show its fragmented nature. I wanted it to look as if original objects were destroyed and the fragments were taken and joined to create this one object. The Red “Stripe” through the middle of the chair is a common diamond shape found in traditional Ukrainian embroidery. It splits the piece in two and symbolizes the clash of the two sides that are in all reality the same. No matter the ethnicity or the language, they are still Ukrainians. The clash causes damage to the country’s people. The black diamonds symbolize this damage and are made of red oak pieces charred by fire. The form of the chair itself is simple, so that the attention is focused at the red split and the detail work.
Teammates: Josh Dycus, Sarah Kate Sommers, Ryan Meiser, and Kendall Putmon
Our team wanted to design a garden that wraps itself around a column and eventually decomposes due to the plants that inhabit the garden. As the pine boards came from the forest and were made into a structure, The plants from the garden will return the structure back into the soil thus continuing the cycle of life.
The second part of the project is understanding how one would interact with the structure. We created a unique hideaway so that you can surround yourself in this cycle.
These two ideas intertwine because we sometimes forget that we are part of this same cycle, we are to enjoy the Earth as it is in the present but our lives are ephemeral in the big picture.