Context
Context
Over the past 3 decades martial arts have become increasingly popular due to their portrayal in Hollywood movies etc. As media
can be very influential on children, many of them take up a martial art to be like their favourite actors, this fact can be seen as
85% of martial arts practitioners are under the age of 13.
Most martial arts base their training around repetitively performing series’ of co-ordinated strikes, blocks and other moves, as
such the form of these moves has to be practiced until they are perfectly ingrained in the practitioners memory. Another factor
that has to be learned as well is the sequencing of moves, this can be difficult when concentrating on all the other factors,
subsequently this is where most beginners to intermediate practitioners make mistakes. This is where the problem lies, when
training with multiple factors to be considered the student becomes over tasked with things to think about, as a result the
student will make mistakes and potentially harm themselves and/or others.
My product will be used to counter the problem of remembering sequencing. By producing a training aid that will utilise
electronically sequenced LED’s the practitioner can follow the sequence fluently while concentrating on their form. Because the
students no longer have to task themselves with remembering sequences they do not overload and can train effectively, once
they begin to remember the sequences they can increase the speed at which the sequencer runs, which will test their reaction
times and train them to act swiftly. In addition to its primary function, the training aid can also be used to develop the students
resistance to damage by strengthening the students arms and legs through the use of controlled damage.
Design Brief
I will be designing and manufacturing an electronic martial arts training aid, that will help practitioners reduce their workload
when training, which in turn will ensure they can focus properly and receive a greater benefit from training. The first product
will be a full scale prototype, used to test the electronics and how they perform when the training aid sustains the practitioners
strikes etc. The training aid needs to be simple yet functional, whilst also being strong and durable to ensure the aid will remain
functional after repeated use.
Objectives
Research
During the research stages of this project I will gather information about the problem at hand by speaking with clients and using
questionnaires aimed at martial arts practitioners, once the problem is clearly identified I will research into relevant topics that
will be needed so a useful product can be designed & made.
Design
In the design stages of the product I will use the information at hand to design a range of products, with feed back from clients
these designs can be developed into a more suitable product. Feedback at this stage is crucial as it will heavily influence the
direction of the project and the outcome of the final product.
Planning
Planning the project the whole way through is crucial to ensure that the project maintains progress and sticks to the time
available to design & manufacture the product. More specific planning will also be used in certain areas of the project such as
the manufacturing stage as any errors here may compromise the product’s quality etc.
Manufacture
To begin with the developed designs will be modelled at a small scale to give the clients something physical to work with and
give feedback on, with the use of this feedback alterations will be made to the model until a final design is confirmed. Once the
design is finalised the product will be made as a 1/3 scale model.
Testing
When the product is made it will be checked over for any problems before taking it to the clients for testing, once checked it will
be taken to the client who will the test the product and give their feedback on points such as the aesthetics, ergonomics and
features etc.
Evaluation
After looking at all of the feedback on the product I can evaluate the product, look at how it compares to the intended designs
were supposed to work etc. I can also look at what could be improved if the product was to be made again, this could include
changes to the product itself or how it is made, such as using more economic methods of production or using more
environmentally friendly materials.
Plan of Action
Assignment
criteria:
Explanation:
Dates:
Context and
Objectives
To determine exactly what needs to be manufactured I will look at the problems martial artists face when
training, with this information I can plan my project accordingly to ensure it tackles the problems.
11/10/11
Clarification of
Problems
With my project structure in place I can research into materials, methods of production, and other areas
that are relative to my project. With my research done I can start designing the product.
Development of
Design Proposal
After researching I can design products that meet the required features etc. With feedback on these
designs I can develop them, then decide which will be the final product for production. At this stage I can
also look at manufacturing methods etc. and decide how the final product would be best made.
Modelling
Before manufacturing the full size product will build a smaller scale model to test how well everything is
placed etc. If anything needs altering it can be remodelled, by modelling first it will save material costs and
potential waste.
Manufacture
With the models made and developed I can select the best one then manufacture it in full size, using the
plan of manufacture that will be made after researching into materials and methods etc.
Conclusions,
Client Meetings,
Recommendations
Once the product is manufactured I can take it to my clients for testing, during this stage they will give
feedback on how well the product works, if any changes need to be made or other recommendations.
Evaluations
With the feedback from my clients and product questionnaires I can effectively evaluate my product. With
this evaluation I can see the strengths/weakness’ with the product and how it could be altered if it were to
be redone etc.
Communication,
Presentation
I intend for my port folio to be very professional and easy to obtain information from, to achieve this the
layout and its content will be placed so it is easy to read and pick out key bits of information. In terms of
communication all client feedback will be noted, and questionnaire data will be shown etc.
Client Profile
From the start of my design cycle I will use two clients who will give a list of specific features that need to be incorporated into my product to
ensure it performs as expected. As my project is mainly aimed at beginners to intermediate level students one of my clients has to be someone who
falls into that category, on the other hand my other client will be an instructor. By using both an intermediate & senior practitioners I can get
feedback that comes from two different points of view.
During the project I will take designs & models to the clients, by doing so they can look at how the product may look and provide feedback which
can be used to improve current designs and models etc. When the final product is manufactured both clients will test and evaluate the product,
additional a range of students can test it and give thoughts on the product. With this feedback I can look over the project and evaluate it, looking
at what could have been changed or done differently.
Client – Intermediate level student
Name:
Age:
Martial Art:
Grade:
Training time
per week:
Daniel Pickles
17
Karate
Green belt
2 hours
My first client is an intermediate
level martial artist who practices
Karate & holds a green belt. As a
green belt my client is classified as
an intermediate level practitioner,
as such he will fall into the range
of my target market. With the help
of an intermediate practitioner I
can effectively design a product
with the customer’s needs in mind.
Client – Senior instructor
Name:
Andrew Nightingale
Age:
40
Martial Art:
Shotokan Karate
Grade:
4th Black
Training time
per week:
10+ hours
My second client is a senior level
practitioner and instructor, using
an instructor as one of my clients I
am able to gather quality research
that will be used in the design &
manufacture of my product.
During the Design process I will
discuss my designs with the client
and use his expertise to refine the
product before the final product is
made.
Primary research into product
requirements
When talking to the senior instructor about my product he provided the information needed as well as sketching a few points to illustrate exactly
what is need within the product to make sure it works well as a training aid.
In the sketches on the left photo the instructor explains
how the electronic sequencing needs to work, he points
out that the product needs to have varying levels of
difficulty between a value of one & ten. For each level of
difficulty there needs to be at least 5 random sequences,
each of which is comprised of combinations of 2 to 10
moves. Additionally each sequence needs a way to increase
or decrease the speed at which the sequence runs.
The second photo shows how the product should look overall and where the LEDs
need to be placed. The sketches show that the product shouldn't imitate the human
form too accurately as doing so will make the product too weak to train powerful
strikes on, instead a torso shape as seen below should be used so it can withstand the
punishment given to it.
By speaking with clients and other martial artists I have
identified exactly what features need to be included in my
training aid for it to work properly and yield the maximum
benefits for the user training with it. The key features that
need to be included are listed below.
Variable levels of difficulty, each with a minimum of 5 sub
sequences.
Speed control that affects all sequences.
Tall torso shape to fit all vital areas on.
Rigid body, that doesn’t deform after being hit.
Method of attaching to the ceiling and floor, connecters
have to be able to stretch to a certain point.
Timer as an optional extra.
Product Analysis
Wooden Dummy
Manufacture
The manufacture of a wooden dummy is a one off
production because each one is custom made for the
user’s measurements. The production of the dummy
starts with the main body being bought, the main
body is then marked up to the correct measurements
& cut into shape. It is then cut into to form the slots
for the arms & leg. With the main work done on the
Ergonomics & Anthropometrics
body it is sanded down then coated in a lacquer. The
The wooden dummy uses anthropometric data of the arms & leg go through a similar process, a bigger
user so the dummy can be specifically made to mirror the piece of wood is split into 3 parts for each arm, they
users measurements with the exception of the leg, which are then cut into shape then sanded down and then
is at a universal set height. The dummy is design to finally finished with the lacquer. The leg goes though
mirror the users measurements to ensure maximum a different process, it is cut into two separate parts
training efficiency. All of the edges are smoothed off so then joined together with a metal pin to form a knee
joint. Afterwards it is sanded down and then sealed
the user gets no splinters etc.
with lacquer. The base is made from pine slats, which
are screwed together to form a triangular base
Aesthetics & Function
Materials
section. Finally the arms & leg are attached to the
The wooden dummy is a very The materials used in the dummy are mostly woods of body and the base is attached with screws.
simple yet functional design, it has some form, the main body is made of Hoop Pine.
been used for the last 300 years, This particular pine is a softwood that has some Conclusion
over this period the design has not characteristics of a hard wood, this is why it is suitable Overall the wooden dummy is a very simple design,
changed significantly, excluding for use in a training dummy. It is fairly dense so it will with little aesthetic features that is made with
aesthetic features. The main not dent when hit by the user. Availability of Hoop functionality in mind. It has some ergonomic
functions the dummy serves is to Pine is quite low as it is mainly found in Australia, features such as matching the users height and
allow the user to improve their because of this I probably will not use it for my positioning of the limbs etc. The wooden dummy
form, ingrain sequences and project. The wooden arms are made from a hardwood will contribute a lot to my product, the basics of my
strengthen
the
arms/hands. because they need to withstand the users strikes over product will be based upon the dummy, as such it
Aesthetic design remains plain on and over. The base is made from something like pine, will ensure my product is effective in its role. My
most dummies, generally a its main function is to hold up the main body. All of product will not use Hoop Pine because of its
lacquered wood is used as the the wood is covered in a lacquer, the lacquer protects availability and cost, a cheaper alternative will have
finish. Rope may also be tied the wood from light wear and tear to an extent. It also to be used to ensure the cost of the manufacture
around certain areas to provide an protects the dummy from moisture.
stays low.
individualised look while serving as The base is held together will simple screws.
padding when striking the wood.
Product Analysis
Standing Punch Bag
Materials
The materials used in making the bag have to be
strong and durable to withstand repeated
punishment. The bag itself is most likely made out
of vinyl or canvas because they are durable materials
that are relatively inexpensive. The filling that goes in
the bag can use many things, depending on the
intended weight of the bag it may be filled with a
mixture of dense foam, sand, wood chippings or
other materials. The filler is also cheap as waste
material from other things can be used. The base has
to be considerably heavy to ensure the bag doesn’t fall
over when hit, as such the base may be filled with
sand or something heavier such as metal plates.
Conclusion
Overall the standing punch bag is a simplistic
design intended to improve the users stamina, coordination and power. After analyzing this product
I can conclude that using either vinyl or canvas to
make the bag would provide good durability for
my product. Designs and logos can also be
stitched or printed on the bag, which improves it’s
aesthetics.
Manufacture
Manufacturing the punch bag is quite simple as most of the work
can be done using machinery. The base is made through the
process of injection molding, it is then filled with the weights.
Next the mid section is made using metal that contains a spring
system with dampening, it is then screwed into the base ready to
attach the bag. Finally cuts of vinyl are taken from a sheet then
stitched to form the shape of the bag. The bag is then filled with
wood chippings or sand etc. To keep the bag rigid & upright
when attached to the base a mild steel rod is placed in the centre.
With all the parts now ready the bag is attached to the base by
screwing in the steel rod, the ends of the open bag are fixed in
place tightly to keep the bag taught.
Ergonomics & Anthropometrics
Aesthetics & Function
The anthropometric data used in
designing the punch bag is very minimal,
it takes into account the height and arm
reach of the average person. Ergonomics
however play a bigger part in the punch
bags function. All of the punch bag’s
edges are rounded off and smoothed for
general safety and so that the user doesn’t
damage their feet when they kick the bag.
The contents of the bag are also taken
into consideration, if the user intends to
improve their form the bag doesn't need
to be rock solid.
The main function of the standing punch bag is to serve as a target for the user to practice attacks on.
It is different from the wooden dummy because it doesn’t aim specifically to increase the users agility
and technique in the same way. The bag can range from 4-6feet in height; the height allows the bag to
be attacked with both the arms and legs and as such is a good training aid for a for someone who
practices a martial art that uses both arms & legs.
The aesthetics of the bag can range from being plain to a little more fancy. The average bag tends to
be more on the plain side, with a logo of the manufacturer or other logos etc. The base of most bags
are made of a durable and rigid polymer, some may have a unique shaped base exclusive to a brand
etc. As far as the finishing goes, the base is left in its natural state with no finishes applied. Attached to
the base is the support pole, this pole supports the bag and keeps it upright after being hit. A polished
or brushed effect is usually applied to the metal to improve upon the overall look of the bag. As for
the bag itself, it is made of a tough canvas weave and covered in leather or vinyl.
Ergonomics & Anthropometrics
To find ergonomic data directly related to my
project I have visited a karate class to take a few
photos of how the training aid will be hit from
different positions.
By looking at the photos & taking measurements
of relevant areas I can effectively determine how
my project will need to use anthropometric data to
ensure it is designed to fit the users data.
In the first photo the students is in the basic
front stance striking the training aid with the
lead arm. In this position I can measure the
maximum reach of the student whilst he
maintains correct form.
In the second photo the student assumes
the same front stance but instead strikes
with the opposite arm.
In the last photo the student is in the
reverse stance, this stance is the second
most used stance in karate. From this
stance the student strikes the training
aid with the lead hand.
Material Research & Testing
To select the most suitable fabric for use in my project I tested all of the options by using two tests & looking at the results of each test to
determine the most suitable option. Before testing any material I cut them all in to a 200mm x 50mm rectangle to ensure the test was fair,
afterwards they were tested using weights to see how much they can hold and stretch. The next test was to sand the material down using a
belt sander to simulate heavy wear & tear.
Firstly the materials are cut into 200mm x
50mm strips to ensure the same amount
of material is used in each test.
Next a hole is punched in to the fabric
using a hole punch to provide a point to
hang weights from.
With the materials now ready for testing, one
end is pinned to the table using a G-clamp and
the material is pulled taught so that an initial
measurement of the length can be obtained.
Gradually more weights are hung from the
bottom of the material, measurements are also
taken at each new increment of weight to see
how much the material stretches. Finally the
material is released and measured to see if it has
permanently deformed due to the weight.
Testing a range of different materials yielded a wide range of
results for how each one stretched under force, the most durable
material tested was real leather, as seen in the top right picture it
deformed very little after holding the maximum amount of weight
with little strain in comparison to some of the other materials such
as the one to the left of the leather. The fine weaved polyester was
unable to hold the maximum weight, the bottom of the material
was torn apart by the weight. By conducting this test I was able to
produce a chart of results which in turn would help me pick the
most suitable material, the chosen material was cotton canvas.
Material Research & Testing
The second stage of my material test was to simulate heavy wear & tear by pressing the materials against a belt sander, although it is
unlikely that any of the materials would face such wear and tear it allows me to look at the materials side by side in terms of durability.
Before sanding the materials five squares
are cut out of some scrap wood, the
squares are used to hold the material
safely in place when sanding the materials.
Once the square are cut out they are
covered in layer of all purpose glue, the
solvent based glue will ensure the material
stays firmly in place. A thin layer is also
place on the materials and they are both
left to dry a little bit before sticking on.
Finally the materials are stuck on to the
wooden squares and any air bubbles are
removed to make the material stick on as
well as possible, these squares are then left
to dry before testing.
Once the materials were ready a table was
drawn out to record the results, the materials
would be pushed evenly against the belt
sander for 5 seconds initially then further
increments of 5 up to 20, if still intact they
were kept on until they were completely
sanded away. The damage for each increment
was noted down along with the final time in
the table below.
By condensing the information from all the
testing in to one table I was able to compare
each material side by side to determine the
most suitable material. (costs for each material
were also considered but not noted in the
table).
Additional Research
When researching in to current training aids on the market I contacted a retailer that specialise in various types off training aids for all types of
martial arts. I sent an email explaining my situation and asked if I could visit the shop to speak with the owner to talk about some of the
products they sell . Unfortunately I have had no reply so I have used other sources to obtain the information.
Research Summary
Context, Objectives & Plan of Action
Ergonomics & Anthropometrics
By having a clear context my objectives were much easier to plan out,
after researching into the actual problem in detail I could outline my
objectives to begin the process of solving the problem. My objectives
outline exactly what needs to be done in order to design & manufacture a
product to solve the problem. After my objectives were in place a plan of
action detailing all the key points within my project was made to keep me
on track when researching, designing & manufacturing.
When building a product that has lots of features that that are going to
be used heavily by humans the ergonomics of the product need to be
done with a high quality, the start of getting the ergonomics right are
researching sizes & shapes such as stance posture, height & reach.
Researching these things are vital as if the product is not designed
bearing these things in mind the product will be far less effective at
fulfilling its function. As the product a lot of important features
included the ergonomics of it need to be researched in depth.
Client Profile & Primary Research
From the onset of the project it was very important to have a client(s) to
work with, by first building up a profile of my clients I am able to tailor
the product to the general needs of the clients, this general outline can
be made more specific with the help of information from the clients, this
may be information such as the required features, sizes, ergonomic
features etc. With this information I can make my product suit the
specific needs of the clients instead of having it only partially solve the
problem.
Analysis of Task & Product Analysis
The second stage of my research is to analyse the task set out, this
involves looking at everything included within the project, ranging from
materials used to designing & modelling, the task analysis gives a brief
overview of all the things I will need to research or cover in my project.
The secondary research in the project is the analysis of existing products,
by analysing the existing products I can look at all the things that make
them good product for use in designing my own product, I can also learn
from the flaws of the products by ensuring mine does not share the same
problems.
Material Research & Testing
The materials used in my product is another important part, as such all
the considered materials that could be used in the manufacturing of the
product have been tested using controlled experiments to determine the
most suitable one to use for the construction of the product.
Conclusion
The research conducted has helped my significantly with the designing
& manufacturing of the product, in terms of designing a range of
possible products the primary research has helped me to better
understand exactly what is need from the product, due to this I can
successfully design the products to suit the client's needs. Other research
such as the analysis of existing products has also helped me design and
manufacture my product, the mistakes made in the existing products has
helped me stay clear of any similar problems that could occur in my
product. In addition to the research into the products, the research into
the materials used has provided me with information that I can utilise
when choosing which materials to use in my product.
Design Specification
Function
The intended function of my product is to allow martial arts practitioners to continue train to a high standard when they are
out of lesson. In a lesson there is plenty of guidance, at home there is none, my product will eliminate that problem by
training the user outside of lesson. The training aid also helps the user to develop correct striking distance, improve their
balance. Depending on the amount of padding in the training aid the user can control how their arm & leg strength
develops. On the side, the training aid will also provide a workout for the user which will increase their stamina.
Aesthetics
The design of the training aid will be based upon a human figure to make the aid more realistic. The wood used fro the
support structure may be left natural or stained depending on its natural look. The aid itself will be a similar size to the
average human to make the aid more useful when training.
Ergonomics
The ergonomic feature will be fairly basic, they will include the rounding of sharp edges for the purposes of safety. The
ergonomic design will also be based around a humans anthropometric data.
Target Market
The target market of my product is mainly intended to be beginner to intermediate level martial artists because they are still
learning the art, as such they would have the most benefit from this training aid as opposed to an advanced practitioner.
Although the product is aimed at lower skilled practitioners, martial arts teacher may be interested as they could incorporate
it into their lessons for students to increase reaction times and balance before progressing etc.
CAD
Computer design software will be used in designing my product to show how everything looks when it is built. When
modelling and developing my ideas, CAD will be used to design the components of my model, CAM will be then used to
manufacture the model components.
Testing
To test my product, it will be first tested by myself to ensure there are no flaws in the making process. Afterwards it will be
taken to my clients who will use the product to test its primary function, they will provide feedback on the final product for
me to use in my evaluation.
Environmental
Issues
My product will be environmentally friendly, the wood used in it can be either reused in other products or made into MDF.
The padding used in the product will be non cross linked polythene, this means it too is completely recyclable.
Manufacturing the polythene also has low impact on the environment. Finally the canvas and metal fixings used in the
product are both reusable and recyclable.
Moral & Social
Issues
There may be some moral & social issues encountered when designing & manufacturing my product, people with injuries or
disabilities may not be able to use the product, as such this may be seen as a problem to certain people.
Initial Ideas
Modelling – Initial
Initially a 2D outline is drawn
on a work plane using line &
arc tools, as seen to the left.
Once the model is designed using
CAD it is exported to quick cam
pro as a stereo lithography file ready
to be set up for machining.
The 2d Outline is then made
into a 3D version using the
revolve Tool.
Using the QCP program the
scale of the model is set up
and checked before machining.
On a new work plane the side
profile is drawn, which is then
applied to the 3D model above.
Any excess material is removed
using the extrusion tool to get
the model seen below.
With the scale set the depth of
the 1st half is determined by
raising or lowering the plane as
seen on the left.
After the basic model shape is
achieved all of the edges are
smoothed off by using the
round edge tool.
Finally the parameters for the
router are set ready for the
program to be launched.
Modelling – Initial
With the software side now ready to go, a
block of styrofoam is cut into the
dimensions need for model, with a little
excess left. Double sided tape is then used
to stick the foam block into place in the
router.
The other half is then machined out by
using the same method as the 1st half.
With everything ready the router is
launched, it runs over the foam taking very
thin layers off with each pass. Finally it
runs over quickly to smooth it down.
With both halves now machined out the
excess material around the body is
carefully removed using a craft knife.
The foam block is then removed from the
router using a thing objects such as a ruler
by sliding it underneath it. The tape left
behind is peeled off then thrown away.
Once the excess is removed from the
model the whole thing is sanded down
using glass paper to start with. It is then
sanded down further with wet & dry to
achieve a smooth finish.
Using a ban saw the foam block is cut in
half leaving only the half of the model.
The other unused half of the block is then
kept for other use.
With both sides now sanded down they
are put back to back for comparison,
any extra material is sanded off till both
sides are equal.
Modelling – Initial
Once the models are equal in size they
have a thin layer of PVA glue applied to
the backs, they are then pressed together.
PVA glue is used as it is strong enough to
hold the lightweight model together and it
contains no solvents which would damage
the styrofoam.
Before using the machine it is calibrated
to ensure it is all set up properly, if it is
not calibrated it might not cut the
material or it could damage it if it cut too
much etc.
With the glue applied the model is held
together suing masking tape, it is applied
tightly to ensure the model retains its
shape when drying.
The next step is to open 2D design
software on the computer and design the
cut out. With that done, the operation
sheet is consulted to obtain the correct
settings for the material in use.
While the two halves of the model are
stuck together the finishing touches are
designed and cut out using a laser cutter.
The parameters of power and cutting
speed are set up and linked to a colour,
then the design needs to be changed to
the correct colours.
The material is first placed in the top left
corner of the laser cutter and is flattened
out. The lid is then closed and the
machine switched on and given time to
boot up.
Finally the program is run and the laser
cuts out the material, after it is done time
should be allowed for any hazardous
gasses to be vacuumed out before
opening the lid and retrieving the cut out
material.
Modelling – Frames
With the glue applied the model is held
together suing masking tape, it is applied
tightly to ensure the model retains its
shape when drying.
With the glue applied the model is held
together suing masking tape, it is applied
tightly to ensure the model retains its
shape when drying.
With the glue applied the model is held
together suing masking tape, it is applied
tightly to ensure the model retains its
shape when drying.
With the glue applied the model is held
together suing masking tape, it is applied
tightly to ensure the model retains its
shape when drying.
With the glue applied the model is held
together suing masking tape, it is applied
tightly to ensure the model retains its
shape when drying.
With the glue applied the model is held
together suing masking tape, it is applied
tightly to ensure the model retains its
shape when drying.
With the glue applied the model is held
together suing masking tape, it is applied
tightly to ensure the model retains its
shape when drying.
With the glue applied the model is held
together suing masking tape, it is applied
tightly to ensure the model retains its
shape when drying.
Modelling – Feedback
The finished initial design was taken to both of my clients to for feedback on points such as the general
shape, the proportions of the parts and specific features such as the shape or position of certain lines etc.
The stomach was the most important part which needed changing, the entire design needed to be altered
to rid the ‘beer belly’ and replace it with a slimmer more muscular design along with redesigning the chest
to have more muscle. Another related point is the shoulder region, the shoulders need to be broader and
the latisimus dorsi made bigger to give the body a V taper, by doing so high kicks will connect more easily
and will not slip off which is a problem faced when using normal punch bags. To complete the more
muscular & athletic design a waist is to be cut out, this will make the design more accurately represent a
human torso and provide a reference point for striking the training aid.
The other points that needed change were around the neck and jaw line, with the current design there is
no neck to target which is in fact a major target area in martial arts, this should be solved by broadening
and flattening the shoulders to make the neck an accessible target. Once the neck has been made
accessible the jaw line needs to be more prominent along with the chin so it provides an accurate target to
train with.
My A-frame model was chosen to be used out
of the available three designs due to having a
more sturdy build. As the A-frame is capable
of free standing and being wall mounted it
combines the abilities of the other designs.
The second frame design was considered too
unstable to be used effectively when free
standing, as it can’t be wall mounted to provide
extra stability it was put aside in favour of the
more stable A-frame design.
The third design was wall mountable only,
because of being wall mounted it would
provide maximum stability and would prove to
be a useful frame, however the frame would be
more useful if it was free standing,
Modelling – Developed
After looking at feedback on the initial
model I redesigned the model, to start
with I altered the 2D drawing to make the
shoulders broader and the waist more
defined along with minor alterations to the
neck.
With the torso section now complete the
finer details around the neck area are
improved upon, initially another profile is
drawn and lined up with the head, this time
the extrusion is only part way through the
model to create a jaw line.
The next step involves using the evolve
tool to transform the 2D drawing in to a
cylindrical shaped object as seen on the
left. The next stage is then sketched on
paper as a rough guide.
Before moving on to the next step the jaw
line is evaluated on its position relative to
the face & head, if it doesn't look right it
can be modified by changing the extrusion
data. This small but important step is
repeated until the jaw line looks right.
Following the sketch on paper as a rough
guide a side on profile is drawn out using
the line tool, once the correct shape has
been achieved the profile is extruded all
the way through the model to remove the
excess material, leaving a general body
shape as seen below.
The next step is to smooth off all the small
edges left by the extrusion process, this can
take quite long as now & then errors occur
due to the amount of rounding off that
needs to be done, the only way to solve
these errors is to redefine the data for the
rounding process
Once the general shape of the body has
been modelled various rough edges are
smoothed off to give a more natural
rounded look, the round edge tool is used
to achieve this.
Finally the developed model is checked
over for mistakes etc. before sending the
data to the router. Once the model is
checked it is machined out using the same
machine and process as the first model.
Final Design
The final design is the design used from
the second stage of modelling, it has been
modified from the initial model to better
suit the user's needs & eliminate any flaws
in the initial model. As seen in the
pictures below the product has a more
muscular athletic look to it rather than an
overweight model, other features like the
waist have been designed to be used as a
reference point as well as adding to the
athletic look. The ‘pharaoh’ looking face
is the chin, as modelling a real head would
be very difficult it is also not
recommended by the client, instead a
bigger head with a jaw line is preferred, as
such the head is made circular with
material taken away from the lower sides
to replicate a jaw line & chin.
Manufacture Specification
Manufacture - Frame
To begin with I drew out a scale diagram of
the metal frame, it was scaled based upon the
size of the model itself to ensure it was the
right size in comparison, the angles and cut
edges were all worked out using
trigonometry.
With the parts now cut out they are all filed
down using a range of files as seen at the
bottom, all the rough edges are removed and
any excess material outside of the cut line is
removed.
After the frame was planned out the metal
was rubbed down lightly using wire wool,
this removed most of the rust and other
stains on the metal making it much easier to
mark out and check when cutting through
the metal.
During the process of filing down the parts,
they are regularly checked by lining the part up
alongside a ruler, if the part is the correct size
the next part is filed down, if not, it is
reworked until it is the correct size.
Once all the metal was rubbed down using
the wire wool I used a metal scribe along
with a ruler & tri-square to clearly mark out
the metal for cutting. The ruler was used to
find the correct distance, then the tri-square
is used to provide a steady edge to mark
along with the scribe.
With all the parts now ready to be welded
together they are aligned in the correct position
on a table, the gaps between the edges are
checked and any other flaws are looked for
before welding.
The next step first involves setting up a metal
vice in a regular vice, the metal vice needs to
be used as it’s resistant to the saw blades
unlike a normal vice. The metal is then fixed
in place and is cut vertically downwards using
a ....... saw, this step is repeated for all of the
parts.
Manufacture - Frame
on the ready on the table
is plugged in and the
is turned on, safety
readied for use of the
If any parts are misaligned due to welding they
are knocked back into place using a hammer,
very light hits are needed as the amount of
misalignments tends to be minimal.
Before starting a jump lead is attached to the
part of the frame being welded to enable the
electric current to pass through harmlessly,
the parts being welded are then given a final
check using the tri-square.
Once all the parts are tacked together the rest
of the welding is done, during this step all the
gaps between the tacked points are filled, this
is where a welding mask needs to be used for
safety, as the welder is creates very bright
sparks it is vital to wear eye protection for the
extended usage of the welder.
Initially a small blob is welded on at the
corners of each edge, this acts like a tacking
pin while the rest of the frame is put
together.
Finally the frame is checked over for any spots
gaps that may have been missed or any poor
welds, the alignment of the parts are assessed
before moving on.
Whilst taking all the points together the parts
are checked against the tri-square to make
sure they remain straight, the heat involved
in the welding can cause the parts to bend
out of shape slightly.
The next stage is to file down the welds to the
stage where they near flush with the frame,
over filing the welds has to be avoided
however, as it could cause the welds to become
weak and it may end up leaving gaps in the
frame too.
With the parts laid
the MIG welder
pressurised gas
equipment is also
welder.
Manufacture - Frame
After the filing is complete the frame is given
another rub down using wire wool, this time
more time is taken to ensure as much rust
etc. Is removed before painting it.
Using newspapers as a cover the frame is
placed on top ready to be sprayed with a
base coat. This first layer of primer acts as a
base coat that covers up any flaws in the
frame, using the primer gives the second coat
a much better quality.
The primer is sprayed on at roughly 15cm
away from the frame and is applied in thin
layers, the base coat is layered up until the
full frame has a quality coating. The frame is
left for 20 minutes to dry, then the frame is
flipped and the rest of the frame is sprayed
to complete the base coat.
After waiting at least 24 hours after applying
the basecoat the second coat of satin black
paint is sprayed on using the same method as
before.
The main problems encountered when manufacturing the frame was
the cutting of the metal, it was a minor difficulty cutting through the
metal by hand whilst trying to ensure the line was followed. Another
difficulty encountered was the amount of time needed to effectively
file the metal parts down before and after welding.
Despite these minor difficulties encountered the frame was
manufactured to high quality and received positive feedback in terms
of build quality.
Manufacture - Fabric
To start with on the fabric section I used a
pencil to draw an outline of the scale model
on some cotton canvas, these outlines were
drawn for all sides of the model to give me
an idea of the amount of material need for
the final product.
With the use of the parts dimensions from the
part before and a book on anthropometric
data I drew out a scale of the final product
with the actual dimensions worked out along
with seam allowances etc.
Once the outlines were drawn they were cut
out using a craft knife, a cutting board was
place under the canvas to protect the desk,
afterwards the canvas was pulled taught and
cut out using the craft knife. Cutting the
canvas was somewhat difficult due to its
thick weave.
With the information on the dimensions for the
final product I began marking on the designs
for the product on a fresh piece of cotton
canvas. I achieved this by using a sharp pencil&
ruler along with a compass, one difficulty was
that the pencil wore down quickly on the canvas
and needed to be sharpened constantly.
With all the parts cut out I used drawing pins
to secure the parts onto the scale model, by
tacking these parts on I could see where
problems may occur when designing the full
size product.
After the final product was marked out it was
cut out into the sections using a pair of textiles
scissors ready to be sewn up.
After the model was checked over & any
possible difficulties noted the parts were
taken off. After taking the parts off I
measured the dimensions & noted them on
the parts for the next stage.
Once all the parts were cut out, all of the
dimensions were double checked for any errors
before stitching to avoid possible complications.
Manufacture - Fabric
Using a dewing machine with a light
coloured thread to match the canvas, I began
stitching along the edges of the parts using
the seam allowance space to stitch in.
Before the electronics could be put in the
holes need to be made for the LEDs, these
holes were made by burning a hole into the
canvas using a soldering iron, using the
soldering iron left a neat hole for the LED to
pop out of.
The first parts that were stitched together
were the back section along with the side of
the legs and the bottom, these sections
provide the base for the rest of the sections
to be stitched on.
All of the holes were tested by pushing the
LED through, if it didn’t go through the
hole was made bigger by pushing on the
edges of the hole with the soldering iron,
this was done until the LEDs fit.
The next sections to be stitched on were the
waist & the side of the chest, from there the
front was stitched on to create the majority
of the body.
A problem encountered with the fabric
section was aligning the LED cases on both
side of the fabric, because of minute
differences inn alignment the LEDs couldn’t
fit through them.
The shoulders were the next to be attached
followed by the neck sections, from here the
head is left open and the body is turned
inside out ready to have the electronics put in
and the stuffing put in.
The problem was fixed by drilling a hole
through the cases, the drill bit was .5mm
bigger than the hole, by doing so it gave
enough room for the LEDs to fit through.
As seen on the left the solution worked well
providing a snug fit for the LEDs in the
casing..
Manufacture - Electronics
Due to time constraints & financial
limitations the electronics used in the
product are used only as a demonstration of
how the electronics would work if the
product was to be made properly.
One major problem with the circuit was
how weak the wires were around the
switch, this was due to the solder applied
to keep them in place. To resolve this a
bigger switch was used and the wire was
just wrapped around instead then covered
up with tape.
To begin with the circuit board has the
resistors put in place & soldered, then the
capacitors along with other components are
put in. The LEDs are put in near to the end
of the assembly.
The next stage of the electronics was to
modify the length of the wire to the
LED’s, this was done by cutting the LEDs
off then soldering a wire in between the
circuit board and the LED.
To finish the circuit the battery & switch are
put in and the excess wire on the
components are trimmed off. Lastly the
micro pic controller is put in, this is the brain
of the circuit.
The circuit is checked once more &
patched up if necessary, it is now complete
and ready to be put in the fabric section of
the product.
The circuit is then tested for any lose
connections & any lose spots are soldered a
little more to ensure a solid connection is
established.
Final Testing & Alterations
After taking the product to the clients they looked examined the product and gave
detailed feedback, some of the main features that needed change were the frame’s design
& small adjustments to the training aid itself.
The electronics were not able to be fully
evaluated as they were only used to
demonstrate how the electronics would work
if the product was to be made in industry.
Instead the placement and fitting of the
electronics was evaluated, from this feedback
it was clear that the circuit board would need
to be placed somewhere where it is least
likely to be hit, such as on the back between
where the shoulder blades. The casing for the
frames on the outer part also needed to be
altered so he sloped upwards from to the
LED as opposed to the current design which
has no slope, the current design is a problem
because it is possible to catch your hand on
the cases if you punch near them. Another
feature that should be include if it were to be
manufactured in industry is some kind of
visual display to show which sequence is
running & at what speed etc. Along with this
it would be useful to have a USB lead to
connect a computer to the electronics, which
could be used to install new sequences etc.
These last two features would greatly
improve the ease of use & usefulness of the
product, however the electronics needed to
achieve this would greatly increase the costs
of the product.
Due to the difficulties of manufacture the
neck did not have a concave shape as
intended, this flaw in manufacturing is
something that would need to be changed
in order to give the neck & face area the
correct shape to train with. Another point
related to the upper section is the shape
of the head, when manufacturing it is
difficult to produce the roundness as seen
in the final design, the final product had
too much of a cylindrical shaped head as
opposed to a real head.
A small point regarding the support of the
training aid was the use of stretchable
cord in addition to the top support, the
extra cord would help keep the training aid
from swinging around too much when hit.
The base of the frame was the main
problem with the product, when it was
free standing it was not stable enough to
withstand the force from being hit.
Proposed changes include having a
telescopic part in the bottom of the frame
to act like legs, if a weight is added to
these legs it should provide the needed
stability to withstand the force from a hit.
Evaluation