GCSE Resistant Materials NEA Portfolio

Countryside

Candidate name: Keira Green

Candidate number: 9063
Centre number: 37463
Centre name: Heckmondwike Grammar School
Context 1: Sustainable Living
In today’s world, consumers are increasingly concerned about
buying products that are quickly outgrown or that become
obsolete before they cease to function. Explore the role of
design in creating products that have an extended lifespan.
While this context seemed a good option initially, I actually
found during this initial exploration that it was harder to think
of original ideas than I thought it would be. While
sustainability is an important issue, the big issue with lifespan
is planned obsolescence which is not something I can design
well for, which meant I found this context more difficult than I
thought I would, although after some thought I did discover
that I could come up with some ideas
Areas to look into:
• Multiuse products
• Making single use products reusable
• Designing products to be multifunctional or
adaptable to other purposes
• Easy maintenance of products
• Recycling in the home and workplace
Investigation of context: Initial
exploration
Assessment Criteria: A01.1
Context 2: Travel Disruption Context 3: Countryside
From time to time events happen that can delay or disrupt Exploring the countryside and getting closer to nature and wildlife
can have beneficial effects on a person’s health and wellbeing.
travel. Explore the role that design can play in meeting the
Explore ways that design can enhance the experience of people,
needs of people involved in this situation. young or old, when spending time enjoying the countryside.
When I read this context, I knew it would be difficult. It would This context felt like it would be the best for me, as a person I
simply be naïve for a GCSE student to think it was possible for have always loved the countryside being a horse rider and
them to solve all the issues in the northern rail or metro transport, having spent a lot of time outside as a child. This one I could
and so the focus of this would be to entertain people during think of lots of potential ideas for quite quickly, but on second
delays and reduce the stress it could put them under. While I did thought a lot of them would be difficult to actually design at
think of some good potential ideas, I felt this context put me in my level and also difficult for me to test out in ‘the field’.
more of a box than I wanted to be in, which is why this mind map However only a few of the ideas are like that, and I still feel I
appears to be more empty than the others have a lot to look into here and a lot of potential still in this
context.
Areas to look into: Areas to look into:
• Types of people affected • Countryside and Urban Areas
• Families/children • Activities in the countryside
• This includes camping, mountain biking, climbing,
• Commuters
• Types of transport hiking etc.
• Public transport (bus, train etc.) • Issues faced in the countryside
• Planes • Litter, accessibility, difficulty for some people (like
• Cars/bikes older people)
Evaluation/summary/analysis: Next steps:
Since OCR provides three design contexts, I decided the best way to explore each On the next page I will be
one initially would be to make a mind map on each and then to note down some conducting some research
into each context in order to
initial thoughts on the outcomes of those mind maps. In the write up that goes
better my understanding of
along each mind map, I have noted down some potential ideas to explore and each one before I decide
some of my thoughts on the contexts themselves. which task I want to take on.
Sustainable Living Travel Disruption Countryside
Source: https://www.c2ccertified.org/ Source: https://www.trunki.co.uk/blogs/trunki-travels/ Source:
The Cradle to Cradle Institute is a non-profit organisation that According to a Trunki survey, 49% of British families are kept https://www.visitengland.com/things-to-do/countryside The
certifies certain businesses as sustainable, ensuring they behind by up to four hours due to flight delays and 65% are British countryside has some of the most picturesque views in
follow guidelines on designing cradle to cradle instead of frustrated by the lack of seating after check in. 56% of parents the world, but not enough people actually spend the time to
cradle to grave. This concept means that rather designing worry about keeping their child/ren occupied at the airport venture into the countryside. According to Visit England, the
something as a means to and end, the product, when it during delays. This worry would be a good problem to tackle in British countryside has 954 experiences listed on their website
becomes obsolete, can be given new life and created into my designing, as it is an essentially universal concern amongst and there are always more. But most people actually spend
something new or serves another purpose. This means that travelling families, especially with young children. Most their time on holiday abroad, so this context may be
instead of many products just becoming obsolete and being parents say the most important items to pack for their children interesting to look into in order to develop a product that may
thrown out (sent to their grave), they are sent to a new life. are electronics to keep them entertained. This would also be increase peoples interest in staying home for the holidays and
For consumers, cradle to cradle good to look into due to parents visiting the countryside. In 2015, there were 3.2 million
design is a win-win situation; You trying to reduce the use of people who visited the Yorkshire
don’t have to buy or replace electronic devices as the primary dales. Comparative to the 65 719
things as often, and they come source of entertainment, and so 911 who went abroad that year, it
from a sustainable source, and thinking about a non-electronic is evident that nowhere near as
this is why cradle to cradle is the product which will still keep the many people visit the countryside
future of design. This refers to 3 kids happy on a long drive or as go abroad; so how do we make
of the 6Rs: Reduce, Recycle and delayed flight could prove an the countryside more appealing
Repair exciting challenge and accessible?

Source: https://therestartproject.org/ Source: Source:

The restart project is a social campaign for more easy and https://www.gov.uk/government/organisations/department-f https://www.theguardian.com/commentisfree/2018/mar/29/
accessible information and parts for repair of electronics in or-transport/about/statistics#latest-transport-statistics litterers-wont-change-litter-zero-waste-national-strategy
order to reduce waste. The project aims to make electronics According to gov.uk, from 2009 to 2017 percentage of flights
and appliances last longer by having information and spare on time has gone down by 7.8%, with most airports having Lots of people are guilty of littering. Maybe not to the
parts easy for the whole of the public to access, which in turn delays which are 15-20 minutes on average, up from 2009 by extremes of fly tipping, but casually leaving behind a wrapper
aims to reduce the amount of electronic waste that gets around 5-10 minutes. Due to increases in delays, usage of from a picnic can contribute to the littering scandal that is
dumped and reduce the effect of companies and planned buses has been going down. It has decreased by 1.9% across destroying our home countryside one bit at a time. Research
obsolescence, which is a huge issue in modern design. It aims England, and the mileage bus services has also decreased due has shown that litter and rubbish in streets and on fields can
to have a library of plans and instructions in order to to reduced services and higher cycle times. This has decreased make them feel abandoned, and consequently, affects
minimise the amount of people who just by an 3.4% across England. peoples happiness and may put So them howoffdocountryside
we fix this?visits.
Research
throw things out when they These changes show how proves that trying to change
don’t know how to fix it. This people have gotten sick of litterers minds is quite literally a
aims to reduce e-Waste and in delays on public transport and waste of time, so how can design
theory aid the sustainability of not having anything to do, as play a part in clearing up the
electrical designs. They also run well as the anxiety delays country, or more importantly,
‘Restart Parties’ which aim to cause. This issue is universal making it easier for people to
educate people on how to across commuters, so would recycle so they are less tempted
repair broken devices be a good issue to tackle. to litter?

Evaluation/summary/analysis: Next steps:

Investigation of context: Research Since I’m deciding on my
In order to find out more about the contexts so I further understand them, context between Contexts 1
& 3, I will explore potential
I conducted secondary research from websites relevant to the contexts.
ideas for both and then
Through this, I have found some problems that I could look into further create a design brief
Assessment Criteria: A01.1 through the next section of the project.
Potential Ideas – Context 1 (Sustainable Living):
In today’s world, consumers are increasingly concerned about buying products that
are quickly outgrown or that become obsolete before they cease to function.
Explore the role of design in creating products that have an extended lifespan.
• Sustainability: 6Rs - Lifespan
• Reuse
• Can a product be remade into something else after it
reaches it’s technical lifespan (i.e. -
https://www.dezeen.com/2017/07/20/kasey-hou-reduce-electrical-waste-flatpack-repaira
ble-toaster-design-graduates/?utm_campaign=Feed%3A+dezeen+%28Dezeenfeed%29&u
tm_medium=feed&utm_source=feedburner
) tried to get as wide a demographic as I could with this
• Can something be designed to be dismantled?
• Rethink
• Can it be rethought so it lasts longer?
• Can it be made of stronger, longer lasting materials?
• Repair
• How easy is it to understand and fix when broken?
• Can it be designed to be simpler?
• Existing products which have short lifespans or become obsolete quickly:
• Electrical products (look at iPhones, for example)
• Headphones
• Wires break easily
• Potentially make a product to prevent headphones breaking
so easily? Or extend the lifespan in another way?
Wider market research
I created a survey on survey monkey in order to find
out more about peoples countryside activities and sent
it to a wide range of people. I asked them for some
personal information as well as information about
their habits and opinions referring to the countryside. I
survey, sending it to lots of people from in and out of
my school. The survey can be found here:
https://www.surveymonkey.co.uk/r/ZHR9QFF
Chosen context – Context 3: Countryside
Why?
As a designer, I found some of my initial thoughts on the countryside more
interesting and I felt they would make a better product when developed
further. I also felt like I knew more about the countryside as someone who
has spent a lot of time outdoors than the sustainability context. The
countryside context felt a better fit to me as a person and as a designer and I
decided on it because I felt that I know more people who the context applies
to and so would be able to have a wider variety of stakeholders who could
all input different views and help me to deign a better product with a wider
market appeal.
Potential Brief 1
Design a product which aims to reduce littering in the countryside and attempts to
make recycling easier and more accessible for people
PROS:
- Recycling is a huge issue in the countryside so tackles an important issue
- Potentially affects lots of people (Everyone who visits the countryside often)
therefore has a wider market impact
CONS:
- Would be difficult for a GCSE Student to fix the recycling issue in British
countryside and naïve to think I could actually achieve such a momentous task
- Only has a few potential options and so could be difficult to create a range of
ideas from.

Potential Ideas – Context 3 (Countryside): Potential Brief 2

Exploring the countryside and getting closer to nature and wildlife can have Design a product to help older people in the countryside struggling with mobility
beneficial effects on a person’s health and wellbeing. Explore ways that design can issues
enhance the experience of people, young or old, when spending time enjoying the PROS:
- Aims to help an issue which many older people face, mobility, and using design
countryside.
• How to make the countryside more enjoyable to aid their experience in the countryside to overcome these issues
• A big issue in countryside areas is recycling - As a product, this has potential to help many people experience countryside
• How do we make people recycle more? where they wouldn’t eb able to otherwise
• Easier? CONS:
• More accessible? - This brief is too specific – mobility issues is quite a specific branch
• More people go abroad than the British countryside - This would also be immensely difficult at my level
• What reasons do people go rather than stay?
• Weather? Here are some of the results from the survey. From the answers,
• Activities available? I gathered that most people seem to sort of enjoy the Potential Brief 3
• Kids find the countryside boring sometimes countryside and mostly people go hiking. I also received some Design a product to help meet the needs of people whose equipment breaks whilst
• Possibly they leave because they don’t like the sight of in the countryside
rubbish laying around – link to recycling issue comments as to what people thought would make the
PROS:
• Accessibility issues countryside more appealing. The most helpful comments I - Helps people whose equipment has broken which can be quite a problem,
• Some people experience issues in the countryside, such as: received were “If it were more convenient to get to”, “If it was dangerous even (for example, climbers safety gear)
• Bikers – broken down bikes/punctured tyres – not easy to fix in rural - When developed, could help many people and potentially hit a wide market
areas with limited access more easily accessible”, “Something to make carrying things
CONS:
• Climbers – broken equipment can be dangerous and difficult to fix easier or something to make it more comfortable when - This is also very specific, broken equipment is too specific for a good design brief
• Walkers – tired, or injured – may need something to help with that camping” and “Make it less dirty and easier or be mobile” - Couldn’t get varied ideas from this particular brief due to it’s specificity
like a walking stick or crutches which are okay in countryside areas

Evaluation/summary/analysis: Next steps:

Investigation into brief and initial I have established my context, brief, primary stakeholder and wider stakeholders, Do some research into
market research which means I can now really focus on further research and consideration of the existing products that fit
needs and requirements of my stakeholders, as well as a product specification. my brief to see what is
already on the market
Assessment Criteria: A01.1/2

Chosen Brief
Design a product which aims to aid people in the countryside in
carrying things and making it more comfortable, taking into account
ergonomics, anthropometrics and aesthetics.
Why?
I chose this brief since I thought it worked well with the context and
could be helpful to many people, since just about anyone who does
countryside activities will have experienced discomfort camping and
many people find it difficult to carry things when camping, for example
taking rubbish away meaning less littering.
Primary Stakeholder:  sometimes and as much as I don’t want to sometimes I end up
My primary user is Caitlin Reid, who has
enjoyed visiting the countryside since she was
little. She enjoys walking, cycling, and ghyll
scrambling occasionally and often plays sport
with her family out in the countryside. I
picked her as my stakeholder as she’s
someone frequently in the countryside and
often having to carry lots of equipment etc,
with big bulky bags that she finds diffi cult to
manage, making her a great representation of
my target market.
Wider Stakeholders:
Potential wider stakeholders include:
• Hikers, campers etc.
• Important to ensure that my target market is as wide as
possible and that they’re satisfied with the product.
• Manufacturers
• Are they UK? Abroad? How would this affect the process, costs
etc.
• Transporters and other shippers (if applicable)
• Shops who would sell my product
• Which stores – places like Mountain Warehouse, Go Outdoors
would be good to sell my product
• Suppliers of any materials used during the manufacturing process
• Also ensuring my materials are as sustainable as possible
• Standards associations who need to assess the product (BSI, ISO, etc.)
Final brief and investigation of
users & stakeholders
Assessment Criteria: A01.3
Interview with primary
stakeholder
Here I conducted an interview with Caitlin. I decided to
interview her in order to find out her needs and what she
would want from my product and any sort of requirements she
thought would be necessary for my design to include.
Q: In regards to the brief, do you think a product along these
lines would be helpful to someone like you?
A: Yeah, I always struggle to carry all my equipment
having to leave rubbish at the site since I struggle to have
enough room to keep it with me. And if you could manage to
find something that could maybe do both, make camping
comfy and aid carrying things, that would be perfect for
everyone.
Q: So if something were to be made which aids in comfort
and in carrying equipment, what do you think would be the
most important features of it?
A: Obviously it would have to be sized well so that it’s easy
enough to carry, or like fit with how people hold things and it
couldn’t be too heavy as that defeats the object of it being
portable. It should be able to withstand weather, since I know
I end up camping in everything from blue skies and sunshine
to rain and storm, so it has to be able to deal with that. Also
needs to hold a good amount, if it isn’t holding much it’s
essentially no good as a product. I think these are my main
things really.
Q: Are there any things you would want but wouldn’t
necessarily need?
A: Well I’d like it to look good, maybe have different
decorations, then more people would like it, but how it looks
is quite important to me, and maybe if it has different
compartments for different things, so if you make something
that has like a bit for food or a bit for rubbish or something.
Or further than that, have it specific to one activity and have
designated storage for equipment for that particular thing. Or
maybe find a way to make it customisable, everyone loves to
have a product personalised to them.
Evaluation/summary/analysis:
I have now finalised my brief, and justified my reasoning for that brief. Now that I
have a brief, I have my primary and wider stakeholders, and have interviewed my
stakeholder in order to gather PUNs and desirables, to take into consideration
when designing my product
PUNs
Based on the outcomes of my interview, I came to an agreement with Caitlin
over a list of Primary User Needs (PUNs). These are priority requirements,
rather than desirables.
Specification Reason
1 - Ergonomics It would need portability and comfort, and
ergonomics would make it more comfortable to
carry.
2 - Anthropometrics In order for it to be easily portable,
anthropometrics are important in order for it to
fit properly with the persons size
3 - Weight Also to aid portability, the product should not
be heavier than is necessary as if it is too heavy
it would be immensely difficult to carry and
would not be suited to the task.
4 - Durability The product would be no good for outdoor use
if it weren’t durable and able to withstand the
harsh weather conditions that it would be
subjected to in the countryside.
5 - Capacity If it doesn’t have a big enough capacity to hold
things, then it won’t fulfil it’s purpose as a
product, so capacity is an important PUN
Further than just the PUNs, I also got a list of desirables that would not
be necessary to make the product but would enhance the product and
make it more merchandisable, improving its marketability.
• Aesthetic considerations
• Many people find that how a product looks will sway their
decision so I should try take into account the look of my
product and how appealing it is to a certain market.
• Different compartments for organisation
• This would just be helpful for the user to keep their stuff
organised and means that things can easily be separated
into categories for easy use
• Specific to one activity, designated compartments
• For example, a product designed for rock climbing with a
specific holder for rope and another for clips, or a bike
product with a compartment for a puncture kit and another
with spare brake pads for example
• Customisable decorations
• My primary stakeholder said that ‘everyone loves to have a
product personalised to them’ which could improve my
market appeal
Next steps:
Investigate into existing
products similar to
mine, and analyse them
Image Features/ Intended use
Duffel bag for camping, used to
store tents, clothes and
everything else. Padded handles
for comfort, expandable for
extra storage (from 40 to 60L)
Bag for basic bike kit, attaches to
the frame from under the seat.
Can fit a selection of small tools,
or small snacks, and has a
pocket for a water bottle or
other beverage.
Contains cutlery in top
compartment, then two other
compartments for food, with
sub dividers in middle
compartment and bottom one
completely empty.
Bloch dance bag, used for
transporting shoes, stage
makeup and accessories to and
from dance/shows easily. While
this is not countryside related, I
own one of these for my dance
shoes and it is incredibly helpful,
and I thought I could take this
forward.
Saddlebag for a horse, has bags
on either side with a sort of
bridge that goes over the spine
of the saddle and clips to the
numna for security in order to
easily carry things while out
riding
Research into similar products and
practices
Assessment Criteria: A01.4
Strengths
- Comfy to carry
- Good amount of storage,
can basically vary
everything you’d need
- Stores the essentials for
riding
- Designed with lightweight
in mind to minimise effect
on riding
- Separate sections means
more organised
- Cutlery included is helpful,
and environmentally
friendly by using less
disposables
- Appealing decoration
- Different compartments for
different things (e.g – a
section for ballet shoes, one
for jazz and one for hair etc.)
- Well sizes, fits everything in
- Minimalistic design, suitable
for anyone and everyone
- Decent storage
- Easy transport of
possessions when riding
out
- Stays in place, attached to
both saddle and numna
- Clips for security
Evaluation/summary/analysis:
Having researched into products similar to mine that would fit my brief, I feel I have gained
more of an understanding of how I can make my product appealing to as many people as I can
whilst retaining originality and I feel I have gained an insight into how other designers have
used materials and different manufacturing processes, which I can look into myself as to
which I believe is most suitable.
Weaknesses
- All just one pocket, so
quite disorganised
- Doesn’t look very good,
looks quite like a turtle
shell…
- Doesn’t store much – only
the very basics/necessities
- Mostly one pocket, which
could become quite
disorganised
- Shallow means lack of
storage for large amounts
of food
- Sub dividers may get in
way, if user doesn’t want
them in a particular
situation
- Basic design could put some
people off buying it
- For dancers who do just
about every style there is,
they may need two, but then
again for more specialist
dancers it’s perfect…
- Looks very plain and
unappealing
- Unorganised within bags
Materials and Costs and sizes
construction
100% polyester (PES), Maximum:
completely PVC free L: 55 cm
W: 40 cm
Sewn by machines, with H: 32 cm
reinforced seams and layered 60L capacity
fabric at important structural
points, foam padding in straps £34.99 – Decathlon.co.uk
Triple-layered carbon fibre L: 9cm
fabrics, leather surface, nylon W: 8cm
straps, outer netting (drink H: 24.5 cm
compartment) 1.8L capacity
Presumably machine-sewn £15.99 – £17.99 (colour
dependent) Amazon.co.uk
BPA free plastic, with band made L: 18 cm
of nylon and elastic W: 10 cm
H: 10.5 cm
Most likely, mass manufactured
by injection moulding
£8.95 – Rexlondon.com
Mesh pockets, waterproof fabric L – 51cm
outer, zippers, elastic carry strap W – 28cm
H – N/A
Machine-sewn
£18.95 –
Dancewearcentral.co.uk
Waterproof fabric exterior with L – 16cm
plastics buckles and clips W – 16cm
H – 23cm
Likely machine sewn and clips EACH POCKET
then sewn in
£23.70 – ebay.com
Next steps:
In order to truly get an
understanding of products like
the one I plan to design, I will do
primary research into a similar
product, doing a disassembly in
order to find out about how it
works and is constructed
 The product I decided to disassemble is a carry case that I used to use
to transport my paints and other art supplies to and from school,
which made it remarkably simple to carry and store away all of my
supplies. I decided it would be appropriate to my brief since it
obviously was used in order to make carrying art supplies easier, a
similar concept to my design, for carrying equipment and such for
camp/biking/other countryside activities. I decided that most
important to look at would be the mechanism that allows it to be
expandable, and looking at the clasps which keep it shut securely so
nothing will fall out. I also decided I should look at the construction of
it, including any standard components and the joints and finish/es
used on the product.
Another thing it is important to note is, looking at the product after a
few years wear and tear and general use, the finish is beginning to
fade in places, and also there are lots of chips and cracks and dents in
the wood, so for my product I should look at potentially a material
that lasts longer and is more resistant to everyday usage and will
preferably not get damaged much if at all when frequently used. The
finish seems to have begun to fade since in my bedroom it was under
a lot of direct sunlight coming through my window, so potentially if
using wood I should research which finishes will do this.
The first thing I decided to look at was the mechanism for
expandability and also the clasps that fasten the case together
to keep it secure.
As you can see in the top video, it is a parallelogram made of
four separate metal bars, which are all linked at the end but
still allow movement. Two sides are fixed to the structure, one
to the tray and one to the main box, and the other two pivot
and as they move, so does the tray. In order to stop it going too
far out, there is a screw which prevents the bars from moving
any farther out, which stops the mechanism from breaking
from going too far outwards.
I then decided to look at the clasps, showing how easy they are
to open and close, and how securely they hold the box closed.
I think that these would be a good option for my product due
to ease of use, a clear interface and how securely they fasten it
shut since if my project comes open when in use, it essentially
defeats the purpose of the product. In the video I demonstrate
the ease of use, and pick up the box in order to demonstrate
the security of the clasps, and move it around to show that
even in use they don’t come undone.

Then I decided to look at the components used, in order to see what I Finally, I looked at the actual construction of the box, and the
could actually make and what I would need to buy in, if I were to do joints used.
something along the lines of this product. The main part of the box, the edges are made with a finger
Looking at how the box opens and closes, it just uses a standard hinge, joint, which greatly increases strength and makes it more
secured by 6 screws, 3 on either side (as you can see in the top image). sturdy. The fingers create a higher surface area for glue to
There are two of these on the box, making it a stronger product. They are attach to and therefore creates a stronger bond between he
incredibly efficient, there is essentially no friction which means the box two bits of material (see exploration of materials and technical
opens smoothly and easily, without needing forcing, which is the job of requirements). This then means that the product itself is highly
hinges. stable and reduces breakages.
As seen in the top right section, the box uses clasps to fasten shut, which The inside trays are created using a mitre joint. This is easier to
I would have to order in if I were to use something like that, which I manufacture than a finger joint, and also looks neater. It means
believe would be one of the best ways to do it. the company doesn’t have to make as many finger joints
Seen in the video to the left is the mechanism for the expandability, (which can be difficult) and also, makes the trays look neater.
shown clearly without the tray. In order to create this, I would need to This is a viable option as the trays don’t necessarily need the
buy in the metal bars, and to connect them they use small circular same level of structural integrity as the outside, as they
connectors, which provide maximum movement with minimal friction to support less weight and are not responsible for the integrity of
make the mechanism as smooth and efficient as is possible. It is then the entire product.
fixed with four screws, one slightly bigger one on the bottom left in order The box itself is made of wood, the bottom of the trays are
to stop it going too far out, and three regular screws. In this particular chipboard and there is chipboard on the inside of the main
product, there are two of this mechanism, and each tray requires two of compartments. It looks like the box was painted with an
these, one on either side of the tray. airbrush, in order to look like it’s made of mahogany.

Evaluation/summary/analysis: Next steps:

Product disassembly Having now completed primary research, I think I’m ready to begin designing my product. I feel I have
gained invaluable knowledge through both the primary and secondary research I have completed
during this and the previous page

Assessment Criteria: A01.4

Material Image Advantage
Acrylic Fairly strong and relatively
inexpensive, insulative, not
very heavy comparative to
other plastics
Plywood Cross-graining makes it
strong and hard to bend,
comparatively light since it
isn’t solid wood, easy to
manufacture with
MDF Inexpensive relative to wood,
saves trees as it is a recycling
process, easy to stain/colour
Beech Hard and tough, strong due
to having a close straight
grain, withstands shocks well
Pine Affordable, lightweight, great
for staining and finishing
Aeroply Could be bent for smooth
edges, fairly strong and
cheap, come in thin
thickness for ease of
manufacture
Evaluation/summary/analysis:
Materials Analysis I’ve now finished researching into a selection of potential materials for the
design, which should aid me later when deciding and considering the material I’ll
make the product from
Assessment Criteria: A01.5
Disadvantage
Non-sustainable, will melt or
burn when exposed to high
heat, joints can be ugly and
very visible depending on
what type of acrylic used
Not easy to shape, not as
strong as solid wood, urea
and phenol formaldehyde
can be bad for people
Comparatively weak, can
crack and split, absorbs
water so can swell, not very
weather resistant and not
durable
Not weather resistant as a
permanent fixture due to it
being moisture absorbent,
heavy and dense so can be
hard to work with, expensive
Not massively resistant alone
(though this can be aided by
finishes) and can be easy to
bend
Not as strong as solid wood,
can crack and split,
adhesives used can be bad
for people
Cost Weight Could it be used for my
product?
For a 3mm thickness, 1m2 338.84 g/m3 Potentially, however I feel
sheet, it cost £46.01 acrylic is not sustainable and
I try to be environmentally
conscious so I want that to
transfer into my designing,
but will be used in the case
of my having no other
alternative
For a 9mm sheet, it costs 600g / m3 I thought I could initially but
around £5.50 / m2 upon further research I’ve
found it isn’t weather
resistant which doesn’t really
work for my product..
£5.03 / m2 for 6mm thick 725g/m3 Could work, this is a really
sheet good option provided I use a
waterproofing finish
For a 9mm sheet, £165 / m2 672 kg/m3 This, on further research
turns out to not be
something I could use. It is
very expensive, too heavy
and potentially hard to work
with, so completely not a
viable option
For a 9mm sheet, £18 / m2 350g / m3 Absolutely a viable option,
provided I can find a finish to
aid in its weather resistance
For a 9mm sheet, 130 gms Potential option, especially if
I opt for rounded corners in
my final design this may be
the easiest material to
manufacture that with.
Next steps:
Begin sketching initial ideas
taking into account the
research across the last few
slides, including product
disassembly and analysis,
context research and materials
research
 Evaluation/summary/analysis: Next steps:
Initial ideas I now have a page full of initial ideas, annotated. I’ve tried to think fully about the Take forward 4 initial
brief, the context and all the research I completed before beginning designing. ideas into iteration.

Assessment Criteria: A0
 This design is initial idea number X – Backpack This design is initial idea number x – lunchbox. I designed
This design is initial idea number x – camp mat carrier. This design is initial idea number x – bike kit box. This product
organiser. The idea behind this product is to help this one as in my initial market research I had some
The idea of this product is to make it easier to carry a is primarily designed for the ease of access and organisation
organise backpacks for when people are out camping comments about litter – people leaving litter due to
comp mat since my primary user remarked to me She that traditional bike bags often lack. The box would clip to the
and this design, in theory, should help make it quicker struggling to find ways to carry it back with them, which back of the bike under the seat or to the handlebar
found it difficult to carry roll mats sometimes since
to access certain things as the bag would be more obviously makes it less enjoyable in the countryside for depending on the users preference as the clip used is fairly
it’s awkward because of their shape and lack of
organised. My justification behind this is I know Caitlin others. I designed this to have two separate manoeuvrable and easy to use. The box would use a metal
comfortable ways to hold them, so I decided to make
told me how she struggles to find specific things in her compartments which can be detached from each other, clasp to fasten for security and ease of interface and would
a carry box for a roll mat with a handle and a this allows the user to pick and choose how many they
backpack and how disorganised her bag gets when she’s have subdivides inside for ease of organisation, the product is
specifically designed size to ensure it fits most roll want (whether both or just one) and allows them plenty
camping as she has a tendency to just throw things in primarily designed to be easier for bikers to store and access
mats (making it more widely compatible with randomly and hope it all fits in right. I designed this to of room for food to carry and to take rubbish away. This
different people’s different brands) but also ensuring their belongings. The box shape may not ideally fit to a bike in
have two larger, main sections. The main sections are would be made from recycled/recyclable materials in any one particular place however it does mean the capacity
it isn't too unnecessarily large, which would make it then subdivided into two smaller sections each of order to create a truly environmentally friendly product can be more easily taken advantage of to the fullest and is not
just as awkward to carry. I designed the handle so it different sizes. which is important to my stakeholder and is quite an specifically for one place on a bike as different users have
would detach at one side to make it easier to open important selling point especially in the modern times different preferences and this allows my product to have a
the lid and get the mat inside. with huge fears over climate change and pollution etc. wider market impact.
Good features Potential Good features Potential Good features Potential Good features Potential
improvements improvements improvements improvements
Ergonomic design Potentially confusing Organised Pocket on front Sustainable and Subdivides in different Easy interface Mroe subdivisions
Easier to carry than roll interface, unnecessarily so, Easy to use (phones/wallets) not Good storage capacity
mat alone potentially handles on environmentally friendly parts to keep food More secure system
Fits backpack so well secure, so look into that Easy interface separate Ease of access
Anthropometrics taken underside to remove the sized theoretically Things may not fit in due to lock onto bike
into consideration need for removable handle Customisable to More parts to allow for Potentially separate
Need to look into
to subdivides – maybe individual needs on the further customisability
have a pocket without a levels within the
manufacture of the handle daily container
subdivide in it?

PUN How well is it How can I improve it PUN How well is it How can I improve it PUN How well is it How can I improve it PUN How well is it How can I improve it
met (1-10) met (1-10) met (1-10) met (1-10)

` 8 Moulded handle ` ` `

2 4 Less clunky around the 2 2 2

corners, make it smaller

3 n/a n/a 3 n/a n/a 3 n/a n/a 3 n/a n/a

4 7 Ensure strong material 4 5 Might get ruined in bag 4 4

5 10 Perfect size for mat 5 7 Sized to backpack, 5 5

dividers reduce capacity

Evaluation/summary/analysis: Next steps:

Iteration 1 – cardboard and CAD Begin iterations on my
models Having completed some initial prototypes and assessing each one for my PUNs, chosen design
analysing each one I have come to a conclusion as to which design to take
forward and develop into what will become my final idea.
Assessment Criteria: A0
This is a 2nd iteration on initial idea number 1 – the lunchbox. Ideally, I
would have liked to have included the clasp I would us for holding
sections together but could not seem to create the very well in sketch
up, the program I’ve used for my initial iteration prototyping. In this
iteration I have included subdivides in the lunchbox and (though it can’t
be told) made this model bigger and therefore more spacious. While
creating this I began to think more about the materials I would use if I
were to choose this design – ideally something sustainable but it would
also need to be food safe, durable and be easy to clean. I would likely
need to use a finish to ensure its food safety and durability, and make
sure its something that would not come off when washed. I think the
design could be developed to not only make it larger, but deeper, to
allow more food and more variations in food that could be stored, but I
think the internal dividers are helpful in separating food.
Good features Potential improvements
This is a 2nd iteration on initial design number 3 – bike box. I decided to
look into use of mechanisms to develop the design, using an external
cantilever to create separate boxes for organisation, and making storage
easier. I decided it would be attached to the bike via the bottom box,
allowing the mechanism to operate while still attached to the bike,
though I couldn’t model the attachment mechanisms on sketchup I
would likely use a standard component for ease of manufacture, like a
tab mounted clip. The use of a mechanism allows for the design to be
more advanced, and therefore has a clear USP, making it much more
marketable. I would need to make this out of something solid to
prevent it breaking when out, and I would also need to ensure the
cantilevers where secure on so that they won’t break under pressure.
Good features Potential improvements
This is a 2nd iteration on initial design number 6 – backpack organiser. I
decided to look into use of divides within the backpack as well as
additional smaller pockets for smaller and more valuable items like
phones. This dividers add to the organisation of the product, without
taking away capacity. The taller back pocket doesn’t have one – this
allows larger items to be sorted, while the second pocket has one about
2/3 along from the left. This allows both big and small items to be easily
divided, while everything can still fit into it. The smaller additional
pockets added mean that items like phones, keys wallets etc. can be
stored securely and accessed more quickly, which is perfect for these
sorts of valuable items.
Good features Potential improvements

Subdivides allow for Potentially have customisable
separation of food and avoids or removable subdivides,
any sort of cross allowing for different
contamination combinations
Plenty of capacity Rounded corners
Handle for ease of transport
Separate boxes for Maybe include divides within
organisation/separation boxes for added
Plenty of storage organisation/clearer purpose
in mind – specific shape for
certain activities/equipment
Rounded corners
Perfectly sized for most More secure pockets for
standard sizes of backpack valuables, potentially lockable
Plenty of storage or just closable?
Stronger

PUN Rating Primary User Feedback PUN Rating Primary User Feedback PUN Rating Primary User Feedback
Caitlin said: “I think the lunchbox idea is Caitlin said: “This ones a great idea. The Caitlin said: “This one seems more helpful
1 6 1 6 1 9
pretty good. I like the layers ‘cause it lets mechanisms look sick! I love how it’s for like school kids than for countryside, but
2 8 me divide up my food and the divides 2 7 expandable – super helpful. I like the idea still a good idea. Could be used for hiking
2 8
within layers are cool. Maybe you could of it attaching to the bike and being able to backpacks, but also you’d need to consider
3 n/a have subdivides specially shaped for certain 3 n/a open it while its still attached, that way you 3 n/a that in the shape – hiking backpacks are
purposes, or maybe something on the side might even be able to get stuff out while usually longer than usual backpacks, so look
4 8 to hold cutlery and stuff? Otherwise it is 4 8 you’re still moving which is good, its super 4 6 more into the shape and proportions of it.
looking good” 5 7 for accessibility” 5 6 Otherwise cool design and would be helpful
5 8 for a wide range of people”

Evaluation/summary/analysis: Next steps:

Iteration 2 – CAD models and Having designed and evaluated a further iteration on my designs, I have improved Take all of this into
sketches the PUN ratings of previous designs and asked for primary user feedback. account for one further
iteration before settling
on a final design
Assessment Criteria: A0
 Final Idea
Now that I’ve completed 3 iterations I’ve
decided which idea I’ll take forward as my final
idea. I chose the bike box as I decided the
cantilever mechanism gave me more to work
with in terms of marketability and having a
This is a 3rd iteration on initial design number 3 – bike box. This
final iteration includes use of divides within boxes for additional USP, and also there’s more of a gap in the
This is a 3rd iteration on initial idea number 1 – the lunchbox. organisation, also I improved the shape on the cantilevers for
In this last iteration on this design I’ve added divides that are market, whereas a wide array of lunchboxes of
aesthetics – the previous square shape wasn’t the prettiest
shaped specifically for certain things – the bottom layer is whereas the new rounded shape is much much nicer, and would all sorts are already available in the market
now specifically for cutlery. I’ve also added a Velcro and require less material, slightly improving the sustainability of the and so my design is unlikely to sell particularly
fabric fastening which would allow a water bottle to be product, which is quite important to me as a designer. On the
attached to the box, so it not only carries food but drink too, sketch I attempted to draw the fastening mechanism that would well.
making it more multifunctional, therefore appealing to a attach it to the bike however this was above my artistic abilities I decided against the lunchbox for
wider market. The box divides are specifically sized to fit and so I would use a tab mounted clip, which is not clear in the
sketch. I also added a second side to the box, for more
aforementioned reason of having no
certain foods (though they aren’t only for that food) I.e. the
one in the top layer divided to the size of a sandwich. gravitational balance, and more storage capacity. particularly unique selling point and not much
of a gap in the market, and the design itself is
Good features Potential improvements Good features Potential improvements
pretty simplistic, and I wanted to challenge
Subdivides allow for Potentially have customisable Separate boxes for Maybe include divides within myself with this project, which the cantilever
separation of food and avoids or removable subdivides, organisation/separation boxes for added
any sort of cross allowing for different Plenty of storage organisation/clearer purpose mechanism would allow me to have.
contamination combinations in mind – specific shape for
Plenty of capacity Rounded corners certain activities/equipment
Handle for ease of transport Rounded corners Final developments I added to the design
were:
PUN Rating Primary User Feedback • An attachment mechanism for the lid to keep it
PUN Rating Primary User Feedback
Caitlin said: “this design is a huge closed as friction and gravitational force will only
1 8 1 7 Caitlin said: “I think this is actually
improvement on the last one! I love my favourite design as of yet! I really do so much, so I added a string tie to keep it
2 9 the cutlery holders. Those are 2 8 do love the dividers for the purpose together
awesome. The only bad thing I can 3 n/a of the box, honestly not sure what
3 n/a
say is potentially having extra else to say! This particular design has
4 8 dividers that’re removable, but I see 4 9
been the one I liked most throughout
you’ve already thought of that so I’ve 5 10 the process and yeah this
5 8
not really got anything else.” development is great!”

Evaluation/summary/analysis: Next steps:

Iteration 3 – sketches Having designed and evaluated the final iteration on my designs, I have chosen Draw up a technical
the design to be taken forward as a final design, specification

Assessment Criteria: A0
Solidworks Model Technical Drawings and dimensions

Technical Specification Evaluation/summary/analysis: Next steps:

On this page I’ve included a scale model drawn up on Solidworks of the final Plan of making and
product, as well as a detailed technical drawing with all dimensions labelled onto cutting list
Assessment Criteria: A0 it
Task + timing (minutes)
Cut and make a mock-up cantilever
mechanism (15)
Create templates on 2D design to be
laser cut – boxes + cantilevers (30)
Laser cut parts
Glue boxes together (20 + drying time)
Cut dowel to size for pivot points (45 to
mark and cut 28 pieces)
File dowel down to size (dependant on
amount needed to file, but 15-25)
Glue dowel to the outside edge of the
cantilever (10 + drying time)
Make the lid on Solidworks to be printed
(20) and print parts (takes a few hours)
Cut, shape and drill wood pivot points
(about 20 per part, total 80)
Glue pivot points to wood
Cut dowel to size (for pivots) 5 min
Put pivots and lid together, file and glue
dowel (30)
Plan of making + cutting list
Assessment Criteria: A0
Materials + Tools Hazards + safety
Material Part Size (mm)
Card, craft knife, split pins Cutting self – careful with craft knife
6mm laserply Base for big box 120*240
Computer n/a “ Long side for big box (x2)
“ Short side for big box (x2)
6mm plywood, laser cutter Laser cutter safety considerations:
ensure adequate ventilation, check
power and speed settings, ensure air “ Base for small boxes (x4)
assist fan is being used and do not look
directly at the beam “ Long side for small boxes
(x8)
PVA glue, paintbrush Careful not to glue self to product, or “ Short side for small boxes
product to other surfaces (x8)
5mm dowel, coping saw Sharp object (saw) – careful to always “ Long pivots (x4)
cut away from self and have dowel
secure in a vice to avoid the saw
slipping. “ Short pivots (x8)
Rectangular file Careful not to file fingers, keep hands 5mm dowel Cantilever pivots (x28) 12
well away and use both on the handle of
the file “ Lid pivots (x2) 120
PVA glue, paintbrush Careful not to glue self to product, or 6mm Lid (x2) 120*120
product to other surfaces plywood
Computer, 3D printer n/a “ Lid pivot points (x4) 6*6
String Lid fastening mechanism
Plywood 6mm, coping saw, file, Saw/file as aforementioned
sandpaper (rough + smooth), pillar drill Pillar drill hazards, drilling through hand,
splitting of wood, sawdust etc. – use a
guard, and ensure supervision
PVA glue, paintbrush As aforementioned
Coping saw, 5mm dowel As aforementioned General workshop safety applies as always, hair tied
File, PVA glue, paintbrush As aforementioned back, goggles and apron on and blazer off etc. as is
standard and ensuring correct methods and
supervision for certain machines (namely, pillar drill).
Evaluation/summary/analysis: Next steps:
Now having written up a plan of making and cutting list I just need to get my Begin making the product
materials and begin making the product itself!
 Varnish soaks into wood and gives it
an additional protective coating,
making the wood last longer. Some
varnishes add extra water resistant
qualities to the product, and is there
to provide a hard shell coating which
is scratch and yellowing resistant.
They are generally used when wood
grains and tones are meant to be
Varnish shown for a natural finish, and adds
gloss and protection. Sealer
Sealer underneath the varnish means
the varnish holds better and has a
smoother finish than just on its own
and has a slightly darker finish while
still retaining the visibility of the grains
and the natural finish. These two being
layered together means that it has a
higher resistance to water and better
protection from scratching and
yellowing, making this a perfect choice
Sealer And Varnish for products needing a natural finish
and resistance to all these things
Sealer And Wax
Oils are usually used to provide some
extra gloss or shine to a product.
Danish oil in particular is used to
create a hard satin finish with fairly
high resistance to liquids. With it
being non-toxic and not slippery, it is
an ideal finish for products that come
into contact with food or children.
Danish oil Teak stain
Using three coats of Danish oil
created a darker colour, higher
shine and further brought the
grain out in the wood. In addition
to these aesthetic bonuses, the
extra coats add higher water
resistance and make the finish
stronger so that it’ll last longer.
Danish oil (3 coats) Oak stain
Exploration of materials and technical requirements
Joint images all from Hodder Online Textbook, as the images of my joint were too poor res.
Solvent based sealers like the one
used in the photo (left) are used to
seal the wood to moisture. Sanding
sealer particularly is used as a quick
drying first coat before applying a
varnish or wax. It also raises wood
fibres so that it can be sanded to a
smoother finish and helps other
finishes stay on and last longer.
Wax is used on top of sanding
sealer to create a smoother finish
and has some level of
waterproofing, so can be good for
furniture products however hot
water can lift it off so if a hot
drink, for example, is put down on
it, it will likely leave a mark since
the hot water lifts the wax off.
Stains are often used to add or change
the colour of the timber, and brings
out the grain in the wood, as seen in
the photo (left) where the grains are
more visible than without the stain.
This stain is teak, made to imitate the
colour of teak wood. The only issue is
that the stains take a few coats to
come out properly, and as visible in
the photo, they don’t come out very
well if you don’t use enough coats
Stains are often used to add or change
the colour of the timber, and brings
out the grain in the wood, as seen in
the photo (left) where the grains are
more visible than without the stain.
This stain is oak, made to imitate the
colour of oak wood. This stain is
particularly dark, so didn’t need many
coats however dark colours are often
overpowering so you have to be wary
of that when using stains
Assessment Criteria: A01.5
This is made by cutting identical 45°
angles and gluing them. While it is
fairly weak, none of the plies were
showing which made it look more
presentable, this being the reason it is
often used for photo frames where
presentability is more important than
strength. It could be strengthened
using a dowel joint or standard
Mitre Joint components like nails or screws
A half lap joint is made by overlapping
pieces. This creates more surface area
between the two pieces, therefore
making it stronger than a standard butt
joint. While alone it is fairly strong, it
can easily be strengthened with dowel
if deemed necessary. The issue is
neatness, as shown in my example
(left) it has to have angles that are
precisely 90° else it won’t fit properly
Half Lap Joint and appears messy.
A finger joint is made with intersecting
perpendicular rectangular cuts, Which
create a bigger surface area in contact
with the glue which makes the joint
the strongest tested. While this joint is
incredibly strong, it is highly time
consuming to make by hand due to
the precise nature of the joint, seeing
as the ‘fingers’ have to be exact in size
and exactly 90° in angle to make sure
Finger Joint they all fit together.
A dowel joint is made with dowel
inserted into drilled holes and glued.
This supporting rod of dowel makes
sure this joint is much stronger than a
simple butt joint. The issues with this
joint is the necessity for high accuracy
in drilling, ensuring that they line up
exactly straight between the pieces of
wood so the dowel goes straight in
Dowel Joint
and ensuring it goes in at 90° to
prevent the dowel coming out the
other side of the wood.
Before beginning making my product, I decided to make a
card model of the cantilever mechanism to ensure it worked.
Using similar measurements to my actual product, I used the
model (which was initially created in 2d design) to
demonstrate and test the mechanism itself. Below is the 2D
design model and the card model, which uses split pins as
pivot points.
Once I’d tested this model of my mechanic, I began modelling
the boxes and the cantilevers on 2d design in order to use the
laser cutter to cut them out. I chose this method as it allowed
a higher degree of accuracy, and for the finger joints to fit in
together correctly, as finger joints require a high degree of
accuracy in cutting. Below is the 2D design model.
Once I’d laser cut the parts, The next thing I had to be sure of
was that each of the 5 boxes fit together properly, and there
was no overhang, which I would need to fix to ensure it
closed together. After filing one of the pieces where the
wood split (shown above right), I glued together the parts
into place, using PVA glue. Having used the laser cutter, I
could be sure that each piece was exactly the right size and
would in turn fit into place, so this method eliminated the
worry of pieces not fitting together properly. I glued the
boxes using PVA and left them to dry overnight.
Making diary
When making the lid, I ran into a couple problems in the
design itself. Initially, I was going to make the lid out of
plywood, to match the rest of the box. However, I realised
that I would struggle to drill a straight hole through the edge
of it, for the pivot, and it not break. It would be impossible,
therefore I changed my tune. To begin with, I thought about
making the pivots on each edge and only be a couple cm into
the wood, however with further consideration I realised this
After gluing the boxes, the next step was to cut the dowel to wouldn’t be strong enough. Below are some of my initial
size and put it in the pivot points. I cut a piece of 5mm dowel sketches for the updated idea for the lid.
down into 13mm pieces, as the holes were 12mm and I allowed
1mm room for mistakes, which could be filed off if necessary.
Once the dowel was all cut down, I put the dowel into the box
and joined them up with the cantilevers. Here was my first
problem – despite extensive measuring, they were somehow
too small. Below are images of my first set of cantilevers, not
fitting.
Finally, I settled on 3D printing the lid – this would allow me
to make exactly what I wanted, without worrying the wood
would split or crack. Below are the Solidworks model of the
lid and the lid on the final product.
After this, I remodelled the pivots on 2D design to be recut. I
added 1mm to the short pivots and 2mm to the longer ones. In
retrospect, I could have re-measured the actual boxes rather
than calculating based on how far apart the boxes were when
closed. My second set of pivots were also too small, although
less so than the first set. After this
second trial I did take a ruler and The last step to making my product was to attach the lid. To
measure the distance, rather than do this I made 4 pivot points – little rounded pieces of wood
trying to use maths to figure it out. with a hole drilled through them, which would attach to the
Here’s the notes I used as I was box and allow the lid to open by rotating around these points.
attempting to calculate the length. When making these, due to their small scale, one cracked,
however the rest were fine. Once I’d made these, I cut 2
pieces of dowel to size, glued the pivots to the corners of the
Finally, having measured the distances out the cantilevers fit. I box, and put the dowel in through the lid. I once again glued
put the dowel in and glued it on the outside, to prevent it the dowel in on the outside, to keep it secured.
slipping out, while still allowing it to rotate in the side of the
actual box. At this stage I tested the mechanism worked
smoothly, which it did. With the main body of the box
complete, my final task was to make and attach a lid – this
came with its own challenges.
 Differences from my final iteration to final
product and justifications
• Purpose – I decided to change from a biking box to a
first aid kit during making as a realised this would be
much more marketable and necessary.
• Lack of dividers – I decided, with the first aid kit, that
dividers may just get in the way so during making
decided against making them, though in retrospect I
actually think this was a bad decision as the dividers
would keep the kit tidier.
• Lid material – I initially wanted to make it out of
wood, however the need for accuracy and the pivot
points changed that to 3d printing, as detailed in my
making diary.

Final

First Testing - strength
To begin my testing, I decided to take my product home in
order to see whether it could support weight within the box, to
ensure it was strong enough to support full first aid kit. While
at home I did not have a full first aid kit, I tested it out with
just about everything that I had – including a reusable ice
pack, which proved to me the boxes could hold a decent
amount of weight. The strength was also accidentally tested on
the bus home – the box was dropped onto the floor of the bus
as it stopped quickly, and there was no evidence of impact,
which is testament to my choice of materials and
structure/joints, as it did not break when dropped quite heavily
on a hard surface. I rigorously tested the durability of it too, as
I carried it round the house extensively with all the objects in
it, ensuring it could carry these items for a long time and
wouldn’t break, which is very important for this sort of
product.
Initial Testing + evaluation
Assessment Criteria: A0
Second Testing – field testing
Next, I took my product actually out into the
countryside. I actually forgot to bring my phone so
have no photo evidence however I can say I gathered
the following information about the product.
1 – positive – the product withstood a lot of force, carrying a
full set of first aid kit while in my bag and while being carried
by hand. I was worried that the bases on the boxes might come
out with the amount of pressure on them however they stood
up to the task really well, which was a huge positive!
2 – negative – the box was awkward to hand carry, so for
further development, I would add a strap for easier hand
carrying. While it was fine in my bag, the fact it is fairly
chunky and awkward, so I would think about different ways it
could be carried.
3 – negative – the rain got soaked up a little by the wood, and
especially living somewhere like Britain where it’s immensely
rainy, this isn’t ideal. After this I think I would reconsider the
materials I chose to make the product out of, or potentially
consider adding a water proof finish. The other thing is – PVA
glue is water soluble, so I would look into other adhesives as
the rain started to wear out the glue at some of the cantilever
pivot points and around the wood pivots for the lid.
4 – positive – the capacity of the box was perfect – all the kit I
brought fit (this included bandages, plasters, antiseptic, a
medical sewing kit and a couple other things) without leaving
too much spare space. The other thing is the separate boxes
kept everything organised, which is precisely what I was
aiming for with the product. The only way I think to improve
this is potentially have smaller subdividers within the
compartments of potentially the top layer or middle layer of
boxes, though I think I should keep the bottom one completely
open as it allows bigger things to be stored (ie the ice pack)
All in all, a positive experience – all the things I set
out to achieve with my product I achieved, and I
think I greatly improved it during the designing and
making process.
Evaluation/summary/analysis:
I’ve now tested the product first hand at home, and evaluated it against the
PUNs, talking to Caitlin and getting her opinion.
PUN assessment and primary user feedback
As the design was completed and I’d done a little testing
myself, I decided to evaluate the design against my primary user
needs.
Specification Evaluation
and rating (5)
1 – Ergonomics - 3 Whilst the design in itself isn’t particularly ergonomic and is
chunky and uncomfortable to carry, I rated it a 3 as it is carry-
able and can be held fairly easily
2– The size of the product was partially gauged between the
Anthropometrics - capacity necessary to hold a full first aid kit and the size of
4 boxes that can be carried easily, and I had a few different
people carry it and asked how the size felt for that, and most
said it was okay, hence me rating this at a 4
3 – Weight - 5 The use of plywood meant that the product was immensely
light, which made it a little easier to carry. My primary user
said that weight was important to ensure anyone could carry
the product, and so I chose a light material.
4 - Durability Having tested the product a little in terms of strength and
durability, I rated this a 4 as it was strong enough to carry
everything and didn’t break with brute force and trauma, the
only thing that seemed to affect the durability of the product
was weather conditions like the heavy rain I took it out in.
5 - Capacity I made sure that the box would have plenty of room for
everything necessary in a first aid kit, and so I rated this PUN
a 5 as the capacity seemed perfect for every essential piece
of kit for a first aid kit.
Feedback:
After this analysis and testing, I spoke to Caitlin, who said this:
“Having seen the finished products and the results of your testing, I
have to say I’m super happy with this product! During design I was
quite surprised to see you change the design from camp equipment to
first aid, but it really paid off – this, to me, is a much more marketable
product that’ll suit a wider range of people. I still love the cantilevers,
the way they look and move is so nice, and the box fits all my
requirements and I’m super happy with the work you’ve put in to get
this up to my standards! The only things I would improve are the ease
of portability (though I see in your testing you already thought about
that) and ensuring it’ll be up to scratch with weather. The other thing is
aesthetics, while the product looks really really nice it’s also a little
boring and bland, so maybe some colour to make it more interesting?
Or a design, potentially on the lid? All in all, I’m really happy with
this!”
Next steps:
Asking for wider
feedback from a range
of people

Market feedback 1 – Katie Green
The first set of feedback I gathered on my product was my
little sister – Katie. As a footballer, she frequently visits fields
etc. to practice her skills, and is often getting injuries. As such,
I decided she would be a good port of call for feedback – she’s
very in need of a first aid kit. I got her to look at the product,
and tell me what she thought.
She said: “I think this is really cool! I like the extenders on it
because it makes things so so easy to access. It’s super helpful
especially since our first aid kit is a mess being just one big
box, so it is well designed. Only thing I would say is colour
because it looks quite boring to be honest and maybe a more
secure fastening mechanism, the string will fray over time.”
She also took the first aid kit to her football practice, in order
to field test it. Due to GDPR, she was not allowed to
photograph during practice, so I have no photos of her taking
it but it managed to not get broken during practice, and by her
report, was “frequently hit by the ball”. Many members of her
club said the product was “cool” and “looked fancy”, so from
that I can gather that the product I’ve made is aesthetically
pleasing, and suits multiple audiences – from the 12 and 13
year old girls at my sisters football club, to the instructors at
my kickboxing club, to the other people I’ve gotten primary
feedback from. Which tells me that the design suits a versatile
market, which is vital for marketability.
Wider Market feedback
Assessment Criteria: A0
Market feedback
2 – Friends
The next set of feedback I
asked for was from a group
of friends I sent pictures to
and asked for feedback from.
The array of people involved
range from a year 8 cyclist to
a year 11 rock climber, so I
was further testing the
marketability of the product
by asking a wide range of
potential buyers. I’ve put
screenshots of all messages
received and quotes from
others about the product
here:
Anwen Beck – “nice design! The lever things are
really good the movement is so smooth and
satisfying. I love the separation in it because it’s
really neat and tidy and you know I love that.”
Manswi Mehta – “The overall product looks
fantastic and I believe it fulfils it’s job correctly. It’s
very professional, but I’d like to see a bit more
colour. I also really like the fact that despite it being
small and compact, it can store numerous things as
well as categorise each section, like you wouldn’t
find in a regular first aid kit. Good work!”
Reuben Price – “Having seen the amount of effort
you put into this project it’s really nice to see it pay
off in such a good looking final result. I really love
the separate boxes because it’s super tidy and
organised and stuff, and the lid looks really cool too
the 3D printing was a smart idea. Honestly, I think if
you put little dividers or something in the boxes that
would be super cool and definitely a better latch, but
otherwise you’ve done a good job there.”
Evaluation/summary/analysis:
I received a lot of positive feedback on my product, and a couple improvements people could
see, the ones I received frequently were use a better latch mechanism, ensure weather
resistance and add colour/further aesthetics (i.e. Sam’s suggestion of a red cross).
Market feedback 3 – wider
survey
This set of feedback I had my family, and
some family friends, look at and evaluate
my products. Below are what they said:
Jamie Green, 43, Telecommunications
engineer – “This seems pretty good to me, I
can’t count the times I’ve needed a first aid
kit out mountain biking, and I really like this.
I personally like the laser cut wood but I
know lots of people don’t – maybe apply a
finish?”
Sarah Green, 40, human resource manager –
“As a horse rider this seems really good. It’s
the perfect size to fit in my saddlebag for
emergencies. I really don’t think I have a
criticism of it, I really like it!”
Jill Bellhouse, 47, primary school teacher –
“This is super cool! I’m really impressed by
how well made and sturdy it is, I think it
would be really good for me to bring when I
take the year 6 girls on residential trips etc.
It’s super tidy too, which I love”
Daniel Bellhouse, 49, marketing manager –
“Super inventive product! I don’t think I’ve
seen many if any expandable first aid kits,
and it could definitely be helpful to a wide
assortment of people. The finesse on the
product and the ease of use, as well as the
purpose of it makes it an easily marketable
product in my opinion. The aesthetics leave a
little to be desired as the product lacks colour
but beyond that it’s really good!”
This feedback was really helpful for me
seeing what a range of people outside my
primary market thought of the product.
Next steps:
Having received feedback
from a wide array of people
I’m now going to use this to
do a further development
on my final prototype.

Specification How it’s met
1 – Ergonomics - It is easy enough to carry and not uncomfortable,
Met therefore the design is ergonomic enough to say I fully
met this PUN
2– I met this one effectively as I ensured it was not too
Anthropometric big to carry, and had various people hold it and asked
s - met them about the size. This was a key aspect to my
product!
3 – Weight - met I met this one particularly well as I spent a long time
researching into different possible materials and
settled on one that balanced strength with low
density, so ensure it was easy to carry by anyone,
which is a key selling point.
4 – Durability – While the product is durable and very resistant to
mostly met brute force and can hold a lot of weight in it, it doesn’t
stand well under weather and so in development from
here I can take this and look at the materials and
adhesives I chose to improve this factor.
5 – Capacity - An essential point to a first aid kit is that it can hold all
met the first aid equipment necessary, so I tried my best to
ensure it had the capacity to hold everything
necessary without being too big to carry, which I have
been successful in!
Taking on board this analysis against my PUNs, the only one I
didn’t fully meet was the durability of the final design, due to it’s
lack of weather resistance. However, I’m happy that that’s
something I could fix fairly easily, if I were to redo the product,
as that primarily relates to the materials I chose. Other than that,
both me and my primary user are very happy overall.
Viability of final prototype
Assessment Criteria: A0
Differences between final prototype and technical
spec:
• The original design for the box only had two layers, not 3,
which I changed for added capacity and ease of access. I
also began with having a two layered box, which opened on
one side but having thought about the physics of this, the
gravitational misbalance would mean it would tip
consistently, so I evened it out to prevent this.
• The material of the lid – I changed this due to the level of
accuracy necessary which I felt I could only ensure with the
3d printer, and it also allowed a smoother chamfer on the
edge of the lid adding to the ease of motion, which may not
have been as effectively done by hand
• The purpose of the prototype itself – during making, I had a
sudden realisation about the purpose of the box in order to
aid it’s marketability. A first aid kit would be much more
widely used, and the level of organisation in this prototype
would be more necessary for a first aid kit than for camping
equipment. In the end, both me and my stakeholder believe
this paid off for a better final product.
Expanding the brand:
I think that I could take this design and then make small
changes to entirely repurpose the product, for example going
back to my initial desirables – having subdivides within boxes
that are specifically shaped to certain equipment. While this
may not be appropriate to a first aid kit, I could do a box for
rock climbing equipment, with vacuum formed sections shaped
to karabiner clips, or a compartment sized for ropes for
example. This would allow me to have the same base product
and then specify to a wide range of activities, therefore a wider
target market. I could also make this product viable to
customers who aren’t interested in countryside activities, it
could be used for sewing kit, for example. The base product I
have made here can then be used to apply to a wider market
with more specific needs, and therefore allowing it to hit a
wide market without having to massively change the product
itself – this also makes it very commercially viable.
Evaluation/summary/analysis:
Having received feedback on my product, I’ve completed a self evaluation on the
commercial viability final prototype, including how I could expand the product
into a range of products, and the marketability of the design.
Marketability
I believe that over the process of creating this product I’ve
ensured it’s marketability for multiple reasons:
• The product itself fits a wide market – at some point, everyone
is in need of first aid, it’s an almost essential piece of kit. My
product would make this viable to everyone to have a neat and
organised box. It also has a much more aesthetic design than
most first aid kits, which while it is not important when in
need of first aid, is a USP for my product, as the range of first
aid kits commercially available tend to just be green plastic
boxes, as shown.
• I’ve received feedback from a wide variety of people who’ve
all said the product is unique and could be used for many
different purposes. While it is purposed as a first aid kit (and
would be sold fully stocked as such) the product itself doesn’t
have to specifically be for that, it can be whatever the user
wants. Not only is this good for the product as I have made it
here, but also if it were to be commercially manufactured
would allow this one base to suit many different things, which
could all be customised as such
• The product would be sold in major retailers, in both stores
like Boots and Superdrug, but also outdoorsy stores like
Mountain Warehouse and Go Outdoors. This would allow a
range of people to see and buy the product, and effective
promotion of the product.
• I would aim to make commercial manufacture as cheap as
possible allowing the price to be low. This would allow for a
wider range of people to buy it – the average price of a fully
stocked first aid kit is around £13-14, I would aim to sell mine
closer to £8-9, manufacturer dependant, to add to marketability
and make it more widely available to people who may need it.
• My target audience is primarily outdoorsy people, who spend a
lot of time out in the countryside and may get injured when
potentially walking, or climbing, or something like that. These
people often do not bring full first aid kits with them, and I
would aim to market the product to them by advertising it with
people using it out in the country, allowing them to relate and
hopefully buy the product.
Next steps:
A final evaluation of the
strengths and
weaknesses of the final
prototype
Product strengths:
• The product managed to meet all 5 PUNs set by
Caitlin at the start of the product, almost all of which
to a very strong degree.
• The product is immensely strong against heavy
weights being in the box and doesn’t break under
brute force, which is essential especially for
countryside as it has to be resistant to being banged
around in a bag on a hike, for example.
• Very organised, which allows faster access to certain
pieces of kit, meaning faster treatment. With
something like first aid, speed is vital, and can save
a life, which was the primary purpose of this product
– organisation for the sake of ease and speed of
access.
• Aesthetically it is fairly pleasing – many people said
they liked the look of the cantilevers, and the lid
especially, which proves that I was successful in my
consideration of aesthetics during the design
process.
• The adaptability of the product is one of the main
strengths in my opinion – it doesn’t have an obvious
specified purpose, which allows it to be multi-
functional. Not only does this add to the
marketability of the product, also to it’s
sustainability as it’s multi-functionality relates to the
6Rs, namely, reuse.
• The sleek and simple design was a huge upside – it
wasn’t unnecessarily complicated, and it allowed for
an easy interface while still retaining the necessary
complexity for it to be a unique product which
wasn’t often seen on the market.
• The size was well gauged, it allowed a full first aid
kit to be stored while also not being too chunky to
carry around with ease.
Design developments and
modifications
Assessment Criteria: A0
Product weaknesses:
• Whilst I didn’t meet most of the desirables, most of
them would be more viable when expanding the
product as a range rather than in this one particular
context.
• The materials and adhesives chosen were not
particularly weather resistant, so over time the
product would wear down with rain, snow and other
heavy weather conditions. PVA is a very strong
adhesive, however is water soluble and so not the
best choice for a product that will spend most of it’s
life outdoors.
• The use of string for the latch, while it looked sleek
and allowed an easy interface there was not the best
choice in retrospect – it began to fray quite quickly,
and the use of PVA to adhere it to the lid wasn’t ideal
either – it was slightly dissolved in the rain, meaning
the string started to come off.
• The product isn’t ideally ergonomic, while the size is
not a problem, the shape of it can be, especially for
smaller people (i.e. younger people) and so I would
need to look at a way of carrying it that doesn’t involve
just holding it. This would also add to the product in
terms of ease of carrying, and making it hands free
could be vital for certain tasks in the countryside.
• The joints for the lid pivot points were actually quite
weak – at one point one of them snapped off when
opening the lid. This wouldn’t be ideal, as the box
would need to withstand a lot of force, those joints also
needed to be able to.
I’ve covered here all the main strengths and
weaknesses of the product design.
Evaluation/summary/analysis:
On this slide I’ve covered the main strengths and weaknesses of the product,
discussed some potential improvements to the design to improve its functionality
and marketability, as well as how I would change the product if it were to become
commercially manufactured.
Potential improvements/modifications:
• Rounded corners to avoid injury
• More secure latch mechanism
• Stronger lid pivot joints – half lap joints instead of butt
joints
• Strap for ease of carrying
• Stain or colouring on wood for aesthetic, or maybe some
other decoration
• Internal dividers potentially adding to the organisation of
the boxes themselves, maybe activity specific shapes.
•
More weather resistant materials – maybe using a
polymer like acrylic, or a waterproof stain – I would
likely test multiple materials and their resistance to
certain weather conditions
Changes for commercial manufacture:
If I were to manufacture this product commercially, I would
need to make a few changes to the design itself
• I wouldn’t 3D print the lid – this would take too long and
just isn’t commercially viable. I would likely injection
mould the lid, using ABS (Acrylonitrile Butadiene Styrene)
moulded at a low temperature for impact resistance. I
would also likely make the pivot, instead of dowel through
a hole in the lid, attached as part of the lid itself, which
would minimise risk of breakages to the pivot.
• I would cut the wood using a CNC laser cutter due to speed
and accuracy of the machine as well as the specific
technical requirements. I would ensure the pieces of the
boxes tessellate together, to minimise waste material
keeping the manufacture cheaper and more sustainable.
• The pivots would also be cut on a CNC laser cutting
machine particularly due to the accuracy necessary on
them.
• If I were to make the internal dividers in the specific shape
for one activity I would use ABS for this too but likely
vacuum form it as it’s an industry standard technique and
good for mass production.
Next steps:
Do a final development
on the design, taking
into account all the
analysis and feedback
I’ve done/received.

The other idea for dividers within the
box was to have the dividers be
removable which allows for a certain
level of customisability in the
product, one of Caitlin’s desirables.
This might be awkward to
manufacture in a wooden product,
therefore I would likely use a polymer
and a CNC mill due to the need for
accuracy, then die cut the pieces that
slot in.
PUN Rating
1 5
Internal divider model
drawn on sketchup to
show how that would
look and the additional
organisation it adds.
If this were to be manufactured I would
likely use a model like this for the first aid
kit model, and use vacuum formed models
with more specific shapes for any other
models. It seems more appropriate to have a
first aid kit be more generic as the things in
there change whereas other things there are
always certain necessities, and the
specifically shaped compartments for them
may also help reduce loss and damage.

Additions to the modification: 2 4

• I added half lap joints to the pivot points on the lid – these would allow for more strength and 3 5
prevent breakages, as while they were glued on well and didn’t come off much, at one point 4 4
when the box was opened quite aggressively by my little brother as he was looking at it they
did snap, and so I added a stronger joint to prevent this. 5 5
• Carry strap, as mentioned in previous slides the box could be quite awkward to carry round, Spring loaded toggle latch (left) and
and so in order to stop it being awkward to carry I added a strap (as well as making it slightly In my opinion this is a huge improvement bailing latch (right) components – use of
smaller). The considerations when applying this would involve ensuring the strap was attached on my final prototype. The ones I gave 4s standard components in the design would
in a way the wouldn’t impact the movement of the mechanic – either attached to the bottom are anthropometrics and durability. I gave
aid ease of manufacture, and both of
box, or as I drew it, long enough to provide a full range of motion. these 4s as I can’t test the durability of the
product, and I think that even with the these two would be effective in my
• Added a red cross on the lid for aesthetics and a clearer purpose to the design
• Dividers within box drawn to bottom left side, additional organisation and ease of access stronger joints the lid pivots may still be design, as they’d last longer and be more
within product. weak, and I can’t make a perfectly secure than the hand-made string
• Material considerations – wood with waterproof finish, or entirely made of polymer? Both anthropometric design and it still fit fastening and would make it easier to
would allow for weather resistance but can be more expensive however looks much nicer. everything it needs, so I had to sacrifice repair the kit however the bought in
this very slightly for the sake of filling
Wood can be finished or painted in order to waterproof it, and I think that I would rather keep it components may also make manufacture
PUN 5, capacity, as I believe that one is
made of woof than polymers like acrylic, as it’s much more sustainable which is important to more expensive.
more important.
me as a designer.

Evaluation/summary/analysis: Next steps:

Design Modifications All in all, I have a lot of ways I could modify this design both to make the original
purpose (first aid kit) fit in more with Caitlin’s desirables and to expand the product
to become a range of different products, with different inserts and purposes.
Assessment Criteria: A0