• User comfort, User -friendly

• Functional Design - cost effective / clam shell

• Transportability (handle, weight / distribution, size proportions)

• Noise Management ( blower motor - air movement)

• Patient air hose outlet: connection access

• Control panel placement- (access - visibility)

• Power switch access

• Filter access ( change / cleaning)

• Impact - drop test  (4 feet) 

• Rain - test (run-off collection areas)

• Family appearance

        In this project the male, over age 55 user market defined the product be function looking, easy to carry and attractive on the bedroom night stand translated into a two piece clam shell assembly with an integrated handle.   The heart of good Industrial Design is defining the overall 3D layout and styling, which must consider the end goal of a low cost mass produced parts with easy assembly, lead by the human factors and user interface considerations.  

 
Phase 1 Mock-up models

       The above examples are from the Phase 1 Conceptual Design efforts, starting with thumbnail sketches  3 primary conceptual models, constructed of lightweight, white foam board.  The far right, stepped geometry layout model form was chosen as the primary direction, but based on ME blower and PCB component selection, the form needed to be a lower and wider (top view) profile.

  
Phase 2,  10 pages of refined concepts

Final "thumbnail" chosen by the team

      The Industrial Design and Engineering team will typically work the process with crude - basic dimensioned pencil or CAD layouts of the internal mechanical components of the product assembly to define the volume.  This product volume - exterior surface geometry is then looked at from the many user-interface perspectives to develop semantic form (on purpose) and styling concepts.
  

Phase 2 Concept Rendering

      Depending on the product design complexity the 3D development process moves back and forth form 3D to 2D drawings.   The intent is to define the overall envelop and styling direction of the product design based on the mechanical requirements. 
 

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Phase 3 Design Control Drawing (pencil)

       The 3D development process may involve a pure mechanical application, and the material and basic shape or form of the product.  Or it may involve more complicated component assembly.  The simpler it is, the more you need Industrial Design, Human Factors and Styling. 



       The more complicated the assembly, the more you need Industrial Design, Engineering and Manufacturing expertise. These models and drawings may be traditional mechanical drafting, lead pencil on vellum or be generated in a 2D or 3D CAD program.  Once the basic geometric form and function is defined based on mechanical function, human factors and user interface the Designers are free to explore styling which should only compliment and not interfere or impede function.

       The 3D form should also follow a "semantic" logic of the layout geometric shape and form to communicate the purpose and visually and psychologically cue the user as to purpose and proper use.  The styling or 3D shape or form, human factors and user-product interface design should support the end users and target markets in safe and correct use. 

The product or machine design should consider learnability, usability, localization and universal design issues, leading to the interpretation of the products capabilities and use, with the ability to adjust to the specific users unique age, size and proportion and perform it's intended task.

       This 3D development must consider all of these issues along with the materials and manufacturing, tooling and process costs.   The designer must know and anticipate the performance of the  product relating to it's physical properties and mechanical limitations including the structural design, general intended manufacturing, mass production - assembly design.

       Traditionally, Designers and Engineers have been trapped in the metal or plastic box with flat sides, based on materials, tooling and minimum quantity  manufacturing restraints.  Basically, because this has been the most efficient way to manufacture materials the product.  Engineers are known for utilitarian, black sheet metal boxes with big knobs, while Industrial Designers are know for space ship, non functional styling and hidden function.

       The trained Industrial Designer looks for simplicity of purpose and form while communicating proper use, which is the groundwork for the Industrial Design 3D development process and applied semantics.  The product layout, shape, size and form are both artistic and on purpose.

       Today, advances in new composite materials, CAD and Rapid Prototyping and Plastics Injection Molding and Flexible Manufacturing has freed up Designers and Engineers from the flat walls, to allow us to be more human factors friendly.   The rising costs of raw materials, tooling and petroleum based plastics and the wide array of available CAD-CAE-CAM manufacturing processes including molding, tooling, draft angles, aesthetics, assembly, functional, servicability and safety requirements must all be appropriately considered and addressed in order to select the most appropriate 3D design -material process.

     Ultimately, how you execute the 3D process and what 3D CAD model files are delivered, is what it will cost you and your company in the thousands of units, defining the critical path to design and manufacturing success.

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ID Fundamentals