RM: Innovation for, through, and of

ExtremesBy Jason Jones & David I. Wimpenny

De Montfort University

Innov_ex 09 9 May 2009

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RM: Innovation

J. Jones Innovex 09 9 May 2009

through,for,

Extremes& of

RM: Innovation

J. Jones Innovex 09 9 May 2009

through,

Extremes

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LSLighting + Sand =

Fulgurite (fulgurite.com)

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LSLighting + Sand =

+ Metal Powder + Plastic

Powder

Laser

Laser Sintering (LS)

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Laser Sintering (LS or SLS)

3D Systems EOS

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SLA

Stereo Lithography

Apparatus(SLA)

Sap Left for Ages

Stereolithography (SLA)

3D Systems

Terminology

LSSLAFDM

3DP

SLMJetting

USCLENSSLS

RM: Innovation

J. Jones Innovex 09 9 May 2009

through,for,

Extremes& of

RM: Innovation

J. Jones Innovex 09 9 May 2009

for,

Extremes& of

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• Pressure a helmet exerts on the head

Correct helmet Small helmet Customized helmet

What is Custom-Fit?

is:

• A Paradigm where• Digital Manufacturing is• Driven by Customer Data in order to• Produce Customised Products for their Body

What are you going to change?

Customised liner

Padding

EPS

How to do it?

1. Start with a 3D helmet model in the computer

2. Scan the head

3. Morph the helmet design to fit the head

4. Make the helmet

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3D scanning

Automated design

07/04/2023

Result

07/04/2023

Growing Wish List

AIR

(Results: failure. HIC = 2460; peak = 280G)

The Next Generation

The customer is always right.

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Un

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Customer feedback

92% of the motorcyclists

surveyed feel discomfort from the seat when travelling long distances

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Un

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• Results from on line survey: motorcycle seats

Do motorcyclists want customised seats?

Yes, 81.10%

No, 18.90%

0.0%

10.0%

20.0%

30.0%

40.0%

50.0%

60.0%

70.0%

80.0%

90.0%

Customised Seats according to BodyGeometry

Customer feedback

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• Results from on line survey: motorcycle seats

Customer feedback

Yes, 78.9%

No, 21.1%

0.0%

10.0%

20.0%

30.0%

40.0%

50.0%

60.0%

70.0%

80.0%

Willingness to Pay for Customised Seats

up to €250, 66%

<€500, 31.30% >€500,

2.70%

0%

10%

20%

30%

40%

50%

60%

70%

Willingness to Pay

Willingness to Pay and Wait

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What part(s) to change?

StabilityPad (inside)

Comfort

Aesthetics

Cover (sky)

Bottom

Cover (sky)

How to meet customer need?

• What bike part(s) to change?– The Seat

• How to drive the changes?

• What changes to make?

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How to drive the changes?

• Unsuccessful attempts: Scanning Measuring

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• Success: Empirical data from Pressure Map

How to drive the changes?

How to drive the changes?

• What about subjective data (your feelings)?

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Emperical Data (mm Hg)

Subjective Data (Feelings)+ Hybrid Data

(Comfort Map)=

How to drive the changes?

How to drive the changes?

How to drive the changes?

How to drive the changes?

How to drive the changes?

Zone 3

Zone 2Zone 1

How to meet customer need?

• What part(s) to change?– The Seat

• How to drive the changes?– Empirical + Subjective Data

• What changes to make?

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What changes to make?

• Laboratory Stiffness testing:– Establish the dynamic performance of the

standard seat material (benchmark)– Explore the performance of alternative

materials

What changes to make?

• Create a “pseudo pocket sprung” seat– Using CAD & Computer Analysis (FEA) to – Hollow out the inside of the seat– Use the force vs. displacement curves from the

laboratory stiffness tests to design individual “spring” like structures.

What changes to make?

• Using CAD & Computer Analysis (FEA):– Make an array of the “spring” like structures

– Insert them into the seat according to…

What changes to make?

• …the customer defined Comfort Zones with the customer specified stiffness

What changes to make?

• Customised Seat making application

• Customised Seat making application

How to meet customer need?

• What bike part(s) to change?– The Seat

• How to drive the changes?– Empirical + Subjective Data

• What changes to make?– Graded stiffness

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The virtual result

The virtual result

The virtual result

Digital fabrication

• Validated design using: Laser Sintering

3D Systems EOS

The result

Ducati seat

Top side Under side

Learning Outcomes

• Is the right material available?

• How we will collect the data (3D scanner)?

• What regulations might be barriers (CE, UL)?

• Will the market pay for the added value?

RM: Innovation

J. Jones Innovex 09 9 May 2009

through,for,

Extremes& of