Ian Frederick Major: BS Sustainable Product Design and Innovation Eagle Scout

Camper, Hiker, Skier, Ceramics, Wood turner, Photographer, Volunteer

Awards: MasterCAM Mill Certification,

Gold Medalist in SkillsUSA NH Technical Drafting Competition

ERGONOMIC SPATULA HANDLE

BY IAN FREDERICK SPDI-152-01 9/26/11

• Create an Ergonomic Spatula Handle

• For grilling

• Better suited for the user

• Comfortable for all different sized hands

• Easier to hold

• Not many ergonomic designs out there

• Use for it in the market

• Closer to the neutral position

• Puts pressure on the thumb, index, and middle finger reducing stress on pinky and ring

finger

HEXAGONAL CHAIR

• Sturdy

• Eye appealing

• Innovative

• Last a long time

• Symmetrical

• Thought about triangles

• Structure they create

• Idea ,sketches ,models

• Made completely of cardboard

• 3 triangles folded for seat

• 3 taller triangles at angles for back

• Wrapped in cardboard

• Completely recyclable

METAL PROCESSING

Project Specifications

• Key fob primarily cut with jeweler’s saw

• Aesthetically pleasing and functional

• 45° angle

• 1/32 in. chamfer

• Thru hole

• One or more piercings

• One or more exterior or interior Radii < ¼ in.

603 Key Fob

Project Specifications

• Interesting design of 3 parts

• Occupies 3 inch x 3 inch x 3inch space

• Only one piece can occupy a XYZ coordinate

• Completed within 5 hours

• Utilized Manual Machining Methods

XYZ Interlock

COOKING UTENSIL FAMILY

• Ergonomic Handle Design

• Comfortable for user

• Dishwasher Safe

• Safe for non-stick cookware

• Ease of use

• Ambidextrous utensils

• Stylish

• Heat Resistant 500+ degrees F.

SOLIDWORKS

CARDBOARD RECYCLING BOX

GROUP PROJECT PDII

Design Requirements

• Ease of Use

• Lightweight

• Match the theme of the TDS

• Utilize different materials

• Ability to wheel around

• Handles to help move it

• Durable

• Fit small and large pieces of cardboard

• Fit in space provided

• Does not protrude into the hallway due to disabilities

Personal Responsibilities

• Beginning research

• Ideation sketches

• CADD model

• Buying materials and assembly of final

LIFE CYCLE OF CORK

Extraction • Harvested from the Cork Oak Tree (Quercus Suber)

• No need to cut down the tree

• The bark is harvested after the tree is 25 to 30 years old or 70cm in Circumference

• Occurs typically every 9 to 12 years

• Can be done about 16 times

Primary Processing • The Cork is then stored in piles usually on concrete to lower the risk of contamination

• Next the Cork Planks are boiled

• To Soften and Clean

• The cork is then stacked and sorted and cut for making wine corks

• Some will be made in to natural cork and some technical

Secondary Processing/Use

Natural Corks

• Made 2 ways

- hand punched

- machine punched

- They are then sorted into grades by machine then by hand

- and packaged to ship

Technical Corks

• Usually used for Champagne

• thin champagne Cork ends which are cut out of strips of cork

• Agglomerate cork which is ground up cork waste

• the cork then goes through a steam bath to clean and remove 80% of the TCA

• the granules is then dried and glue together

• With a polyurethane food-grade glue and made into long corks

• Which are then cut into wine cork lengths

• the ends from earlier are then glued to the cut agglomerate pieces

Some of the scrap cork can ground up and mixed with a non-toxic resin to create Cork flooring

• Manufactured as tiles and planks

• In various thicknesses

• The baking of the agglomerate and resin makes the cork much more durable

• After being cut the cork flooring is then sealed with polyurethane or wax

• There is very little waste in any of these processes

End of Life • thrown away

• Incinerated

• Recycled – only for bottle corks

though

• There is no way to recycle cork

flooring yet in the market

Human Health Effects • very minimal

• Protection from hot water

• Minor cuts from harvesting and handling

• Inhalation of binding resin after a long period of time could be harmful

Environmental Effects • Minimal

• Transportation

• Sustainable Practice trees live up to 200 hundred years

CERAMICS

WOOD/METAL

TKI BELT BUCKLE

MANUFACTURING

ENTERPRISE CAPSTONE

Requirements

• Start up company, design, manufacture, market, and sell a product

• Group project idea: Knights Out Belt Buckle

Personal Responsibilities

• Plant Manager

• Provided leadership in the workshop

• Assisted in obtaining stock

• Assisted with machining all components in both prototyping and final

• Assisted with MasterCam tool paths for engraving

• Contributed to early prototype designs

TABLE LEG HOLDER

PART OF WORK STUDY UNDER CHRIS GRAY

• Create a Table Leg Holder for the Thorne Art Gallery on Campus

• Safety was the biggest concern

• Fit within existing table dimensions

• Not to protrude farther than Table leg brace

TABLE LEG HOLDER

(CON.)

PRODUCT DESIGN FOR

MANUFACTURING

• Learned how to manufacture a product

• Reverse engineered a 1993 Thule Ski Rack

• Disassembled existing product

• Rebuilt in SoildWorks

• Redesigned for aluminum extrusions

• Created a Bill of Materials

• Costing out every material and process

• Successfully matched existing product MSRP

• Price at REI Online= $199.95 + S&H

• Calculated MSRP Price= $223.94

PRESIDENTIAL

INAUGURATION KEEPSAKE

• Large contribution to final design

• Assisted with machine setup

• Assisted with machining final parts

• Presented President Anne Huot with her personalized Keepsake