jason jones 090506 innovation4extremes v1

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RM: Innovation for, through, and of Extremes By Jason Jones & David I. Wimpenny De Montfort University Innov_ex 09 9 May 2009

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Page 1: Jason Jones 090506 Innovation4extremes V1

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

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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

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Stereolithography (SLA)

3D Systems

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Terminology

LSSLAFDM

3DP

SLMJetting

USCLENSSLS

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RM: Innovation

J. Jones Innovex 09 9 May 2009

through,for,

Extremes& of

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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

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What is Custom-Fit?

is:

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

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What are you going to change?

Customised liner

Padding

EPS

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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

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Automated design

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07/04/2023

Result

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07/04/2023

Growing Wish List

AIR

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

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The Next Generation

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The customer is always right.

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Customer feedback

92% of the motorcyclists

surveyed feel discomfort from the seat when travelling long distances

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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)

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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?

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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)=

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How to drive the changes?

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How to drive the changes?

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How to drive the changes?

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How to drive the changes?

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How to drive the changes?

Zone 3

Zone 2Zone 1

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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

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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.

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What changes to make?

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

– Insert them into the seat according to…

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What changes to make?

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

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What changes to make?

• Customised Seat making application

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• Customised Seat making application

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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

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The virtual result

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The virtual result

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Digital fabrication

• Validated design using: Laser Sintering

3D Systems EOS

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The result

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Ducati seat

Top side Under side

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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?

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RM: Innovation

J. Jones Innovex 09 9 May 2009

through,for,

Extremes& of