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PDM 4

Product Design Portfolio
by

Sinead Hanratty

on 31 May 2013

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Transcript of PDM 4

Situation A local Boutique owner has approached me with an idea to design and manufacture a unique feature chair. The boutique has recently started to sell shoes, she has found it difficult to find the right chair to suit the style of the boutique. The shoes are selling very well and to date the customers have to go into the changing room to sit down and try on the shoes, although when the changing rooms are occupied they are unable to sit comfortably and try the shoe on. My Client Darina Hughes Design Brief I am going to design and manufacture a stylish chair for a local boutique. I will consider the style of the boutique and the various products the boutique sells. The chair will allow people to sit comfortably and try on shoes in their own time. I will interview my client and consider the various features they would like the chair to consist off. It is important the chair works well in the chosen environment and is comfortable for the customer to use. D-Tale Boutique is owned by Darina Hughes and is situated in Crossmaglen County Armagh. It has been opened 3 years and is well established in Crossmaglen. Darina always keeps on trend with the current fashion and supplies clothes for young and older adults which ensures she has a good client base. She recently has added a number of different clothes brands into the shop and the reaction has been extremely good. At the start of October she introduced a shoe brand called Poetic Licence, the shoe brand is very quirky and contemporary and works well with the various pieces of clothing within the shop and the client base has increased throughout those few months. Features to consider Course of Action In order to please my client to the highest standard it is very important that she is a vital part of my design and manufacturing process throughout. Firstly it is important that I get the correct feel of the shop and ensure that any ideas Darina has about the chair are taking on board and worked with to gain the final outcome. Any ideas and concerns she has will be put across when the interview commences. I will then take various photos of the various features within the shop that will help me design a number of ideas for Darina to take a look at.
A number of styles and techniques will be researched to ensure I have the tools and skills to undertake the various procedures needed to manufacture the design chose by Darina. If the design is not viable my client will be informed. Darina will have a say throughout every stage of design and manufacture, my client will be informed of any added features or materials that I may make to the chair. Sinead Hanratty Environment PDM 4
Student Number: 40034932 There are a number of features in the shop that Darina has asked me to include. From the interview that I conducted with her I have been made aware of the various areas of the shop she would like me to take note of and the features that she may not want me to include. She firstly introduced me to the new range of shoes that she recently has added to her shops collection. They are sitting on a mahogany counter. There is a lot of cream and gold’s within the shop from the mirrors and the table to the chandelier and various photo frames positioned throughout the shop. Throughout the years she has picked up a number of unique ornaments and pieces of furniture that work really well together in the shop. She asked if I would be able to carry on the theme she has tried to portray within the shop. There are a number of items throughout the shop that are very eye-catching and stand out as soon as you enter the shop. There is a large marble table with golden carved table legs and frame it is positioned in the middle of the floor on top of a large green rug. Another piece of furniture that stands out is the large mirror golden mirror on the wall, Darina informed me the table and mirror came as a set and really likes the colour and the legs on the table. The wall of the changing rooms has been wallpapered with a very unique paper that shows various landmarks throughout the world, this also stands out a lot. under the large gold table lies a green rug. On the wooden counter there is raspberry tissue paper, this tissue paper is used to wrap clothes in before they are placed into a bag. The colours within the shop that Darina would like me to incorporate into the chair are neutral colours with gold’s and silvers and also the colours in the wallpaper rug bags and tissue paper. Positioning of the chair There is one area in the shop that Darina has in mind to place the chair. As the shop is small there are a lot of rails and floor stands that display the clothes. There is a corner beside the large golden mirror, this corner is beside the counter. As Darina pointed out in her interview she wishes to monitor the customer on the seat and those in the fitting room. Therefore this area is very practical. Client Interview Research Brainstorming Specification To get a more in depth feel of the kind of furniture Darina likes and to make her aware of the various different styles of chair available today I gathered a collection of images portraying various different style of chair. Each chair is very different from the others and they all display different features. Some chairs are fun and quirky while others are more neutral and sophisticated. This area of the interview will allow me to understand the type of chair Darina wants me to design and manufacture and the various features she would like me to include. I asked Darina to tell me what she likes and dislikes about each chair. Target Market
The chair will be made to fit into the surroundings of a local boutique. The boutique owner wishes for the chair to blend in well with the features already in the shop and also be suitable for her customer to sit on.
Function
The chair will create a sense of rest and comfort for the user to relax and try on shoes. The chair will be a key feature in the boutique and will be admired by customers every day.
Maintenance Requirements
The chair should be easily cleaned if marks appear or if anything is spilled on the seat. If the chair has a finish of paint or varnish it may need re-application from wear and tear. If cushion is used the material used for the cushion may need refilled after a number of years.
Product life span and life cycle
The chair will be designed to last a life time with proper care. When the chair reaches a state where it can no longer be used there may be areas such as wood or material that may be recycled.
Health and safety
Health and safety regulations will be adhered to during the manufacturing processes. When designing and manufacturing, the chair will be rigorously tested for strength and stability. Every effort will be made to ensure my client and her customers cannot be harmed when using the chair.
Cost
The cost of the chair will be kept to a minimum and will not exceed £150. The materials used will have a reasonable cost and most of the tools needed to manufacture the chair are available without cost. Quality Control
The chair will be checked for quality and imperfections/damages at every stage of manufacture. Corrections/repairs will be made so that the chair is manufactured to the highest degree. A final quality check will take place before the chair is given to the client.
Quality Assurance
All systems and procedures will be in place to ensure that a quality piece of furniture is manufactured. The client will be constantly updated and consulted on all aspects of the design.
Shape/Size
The shape of the chair will be designed with the help of my client. She will be a main source of feedback throughout the entire design process. The chair will be made to fit one average person. There is one space within the shop where the chair will be situated the measurements of this area will be taking into account.
Colour
It is very important that the chair works well with the surroundings of the shop. There are a number of colour throughout the shop such as silver, gold, browns, creams and green. These colours are very neutral and they will be taking into consideration when designing.
Materials
My client would like me to take the material she uses in the shop into consideration when manufacturing the chair. A lot of fabric is used throughout the shop along with different type of wood from mahogany to beech. There are also various types of steel used throughout the shop and are seen in the mirrors, tables and photo frames. Method of Manufacture: Mannequin Wire Wire mannequins are very popular and are used widely to display clothes and jewellery in small boutiques and vintage shops. The possible design of the mannequin are endless when using wire although they may be difficult to construct. As it is a chair the wire may be uncomfortable when leaning against it. The user mentioned in our interview that she did not need to display anything on the chair, although if i use wire it will allow her to display jewellery and handbags. Fibreglass Fibreglass is currently the most widely used material for manufacturing mannequins. This material has a balanced ratio of weight and sturdiness. Fibreglass mannequins also transport for a reasonable price and can last for a long time with proper care. Fibreglass is easily painted or painted over and can be changed into different looks when necessary. Though fibreglass is mostly sturdy, if it falls, it will completely shatter---making clean-up difficult and dangerous if proper precautions are not taken.







My client does not have a fiberglass mannequins therefore I am not sure if she would like to incorporate a new style into the shop. Polystyrene Wooden mannequins are usually an art feature within a house or shop and very rarely used to display clothes. usually they may have a unique pattern painted on them to ensure they stand out wherever they are positioned. They are usually carved from a large block of wood. Wooden Polystyrene is a hard plastic that is indestructible and has a long-lasting shelf life. It has been used to manufacture mannequins for roughly the past 15 years. It is also lightweight and transports cheaply. This type of material may be injected with dyes to create a variety of eye-pleasing colours. Companies in need of many mannequins at one time benefit from purchasing polystyrene mannequins the because material is cheap and easy to transport. There are a number of coverings that can also be purchased for polystyrene mannequins. Some disadvantages to polystyrene are that it cannot be sprayed over and can be expensive due to the restrictions on styles and moulds. Concept Sketches Concept Sketches This type of mannequin are the more traditional seen in many shops. D-Tale Boutique has two types of mannequin, a polystyrene and wire mannequin. I feel this type of mannequin would be more appropriate as it will blend in with the mannequins already featured in D-Tale Boutique. My client asked me to take into consideration during my design the various features her shop has to offer. This style of mannequin is very artistic and would compliment and chair. the mannequin could be covered using a number of different methods such as mosaic or mirror.
Although it may be difficult to manufacture with the material and equipment I have. It may also be uncomfortable to sit against. This wire mannequin is very attractive with its corset design. It is aesthetically pleasing. If i were to use wire there are a number of other uses the chair could be used for such as hanging jewellery. My client did not intend the chair to have another function other than to sit on it.

Due to time constraints the wire may be difficult to manufacture as it is very delicate and accurate. Each piece would be made and welded individually. A big disadvantage about a metal chair would be the comfort it would offer the customer. A dressed mannequin on the chair may also be very exciting and unique although it may be difficult to ensure the seat matches the style of clothing my client sells. It would also be hard to ensure it does not go out of fashion. This style of mannequin would allow me to choose a fabric that would work well with its environment. There are an endless amount of designs which would ensure the chair is aesthetically pleasing to the client and her customers. Style of mannequin This style of mannequin is very modern Although some may say it may be inappropriate for its use. this style of mannequin may not be comfortable although there are a number of ways the mannequin may be manufactured. Style of Leg This shoe effect takes into consideration what the chair will be used for. The shoe will act as a leg for the chair. There are a number of methods in which I could manufacture this such as wood carvings or moulds. This design has been based on the furniture already in D-Tale boutique. There is a table in the shop that has Queen Ann legs and they have a lot of detail therefore the plain Queen Ann leg may not be appropriate. There are a number of designs that can be incorporated into a Queen Anne leg such as an eagle claw. I have designed two ideas that I could use instead of the simple Queen Anne leg. although these design are very eye catching it may be very difficult to crave an accurate design to fit in with the designs already in places from the table and mirror. This design is very modern and may not work well in the chosen environment. Although the method of manufacture is very effective as I have been trained in how to use a wood lathe and I have access to a wood lathe every day. Development I have created a number of different design which i could create on the wood lathe using solidworks. The middle design I feel works best as it has a vintage inspired style due to research on chair designs. If I was to go ahead with this design there would be four legs manufactured for the chair using the chosen wood lathe design. My client asked me to deign an manufacture a creative and unique chair to be placed in her stylish shop. I want to ensure I meet this requirement in every way, I feel having 4 legs on a chair is the normal thing to have there for i would like to come up with an elegant, classy and unique design for the stand of my chair. Development After looking back on the various photos taking from within the shop I have came up with a design that will work good with other products but have a unique twist to a normal every day to day chair. As I have decided to use a mannequin effect on the back of the chair I thought it may be appropriate to continue the mannequin style on the legs. The mannequins Darina use's are basic mannequins with a pedestal leg. I feel a pedestal effect will look very good as a leg on the chair. The basic shape of a mannequin leg is very simplistic. Although it is attractive i feel to add a twist to my chair i will develop the pedestal leg to work around the features within the shop. For the main pedestal I could use the wood lathe to turn a design. This will work well with the features within the table leg. Many pedestals only have 3 legs, although I feel for extra strength and balance 4 legs would be much more efficient. The most common method of manufacture of a pedestal would usually be a Mortise and Tennon joint. This joint is very strong and indeed may hold although I wish to incorporate a twist to the original pedestal look. Also as i will have a long back regarding the mannequin i would like to design something to ensure the seat is not top heavy. As there is a lot of metal in Darina's shop I would like to work with wood and metal. I have designed a stand that will allow extra strength and balance to the chair.

The outside frame will be made with metal this will ensure it is strong to hold weight. the metal frame will then be welded to a metal tubing where a wooden lathe pedestal will be inserted. Development of the seat As I am making a mannequin type chair I would like the seat to be designed in a way that this style will flow throughout. This design may not be very comfortable to sit on although there is a good flow of style from the mannequin to the seat as it represents two legs. It may be too modern for the boutique. This design would be much more effective and comfortable to sit on. there is a small curve to the seat which gives extra comfort when sitting. There is room at the back for the mannequin to be placed Manufacture Design Idea 1 Hanger Chair This chair is very eye catching and suitable for a clothes shop due to the hanger design. the hangers could be made using aluminum and sprayed a number of colours that would allow it to blend in with the environment. I constructed a model of this idea out of old clothes hangers and stuck them together similar to the design. i sprayed each hanger either gold or white to blend in with the colours in the boutique. The legs are also designed to be made out of hangers although the material would be different then that of the back as it would need to be heavy to ensure weight put on it. Design idea 2 I used flowers, feathers and leaves to create a model of theis detailed back chair. the colour are not suited to the shop although it gives an insight into how the back may look. Design idea 3 Mannequin Chair This model represents how the chair may look with a different seat. I feel the seat would have to be changed in order to make the chair unique. I really like this design and feel it would work very well with the chosen environment. my client wanted a unique chair but noting too modern. I feel this design would be best and this is the design I will start off with whilst manufacturer and developing. I have created a solid works drawing which will be sent to get plasma cut. as there is 4 legs I will need 8 of this design. Final Product Testing A customer was kind enough to let me video her as she tried on a pair of shoes in D-Tale Boutique. In its surroundings Client Feedback Material and Colours I wanted my client to have a say in every decision about the chair regarding colors and materials used as it was going to be placed in their boutique they should be very happy with the final product I researched a number of materials that i felt would work well when placed in the shop. I took the materials to Darina for her decision. She loved each pattern and the concept of eac but immediately she fell in love with a button and measuring tape material and loved all the colour. i ordered a sample piece to ensure it was good and took it to her to see it, she loved the feel of the material also. We both decided to go ahead with the material.

I asked Darina what colour she would prefer the metal to be powdercoated and she chose a rasberry pink as she felt it would break up the gold and would work very well with the tissue paper and bags. The first stage of manufacture was the making of the mannequin profile. the profile was designed then transferred onto plywood. the design was then cut out using a coping saw and band saw. the profile was the sanded to ensure a smooth finish. this stage was quite difficult as it was very important that both sides were symmetrical. The base of the chair has been made using a piece of 20mm beech. An angle was devised to suit the use of the chair to ensure it was comfortable. The angle ensures extra comfort for the customer The base was attached to the mannequin profile using screws and glue for extra strength. Three supports were added to the back of the profile to ensure good strength when the customer puts pressure on the back of the chair. these supports were attached using dowel joints and glue. To construct the seat of the chair I used three mahogany planks and joined them together using biscuit joints. The chair was then sanded to cover up the joints. After creating a design for my pedestal leg I practiced a number of skills on the wood lathe and used you tube videos to help me create the design I wanted. I then glued four square pieces of wood together and clamped them over night this allowed me to create a large piece pf wood for the pedestal. This wood was then planed and sanded before put into the wood lathe. I used a number of tools to create the desired shape, the piece was then sanded whilst help in the wood lathe. After coming up with the idea of using metal i created a solidworks drawing for the legs and the under side of the seat. These drawings were then sent to the plazma to be cut from metal. I used a large piece of metal tubing to hold the pedestal leg. this tubing would be welded to the plasma cut legs and another to the underside of the seat. the pedestal leg would then fit into this tubing. Once the plasma cut legs had arrived I decided to make wooden panels to fit in between them to ensure the chair was strong. I cut these legs from mahogany and used a band saw to cut them out. I then used a planer and drum sander to ensure they were smooth. To legs for either side were stitched together using a welder. This would ensure when drilling through them to attach the wooden piece they would be exactly the same . To weld the legs to the metal tubing I created a jig. there was a square piece attached to the base to raise the metal tubing. The legs were then screwed to gether with a piece of chipboard between to ensure they were the correct width apart. I then used a block of wood that would allow me to ensure each leg would be square and balanced correctly. Once I came up with a dsign for the seat of my chair I researched a number of ways in which i could create this design although after further research it was evident i did not have the skills to create a design like this. i contacted a local furniture maker and asked him to help me create it. i was along side him when he created this design and watched every step lending a helping hand whenever possible. A piece of metal tubing was then welded to the plate for the under neath of the seat. this would hold the pedestal leg in place. A countersunk bit was then used to ensure the screws would be flush to the surface. Sponge and had been added to the mannequin to get the desired shape. Throughout these stages i visited the upholster on numerous occasions to ensure they shape of the mannequin was correct. Material was then added to the sponge mannequin It was time to attach the mannequin to the seat. I completed this using a frostner bit which would allow we to drill deep into the seat to ensure a screw would go far into the base of the mannequin. if the screw did not travel far into the base of the mannequin it may be prone to moving. " Its beautiful, it is so original I have never seen anything like it before. It really works great within the shop and its do comfortable to sit on. " The metal plate was then attached to the under neath of the seat using screws. It was important to ensure this plate was in the middle of the seat as it may cause imbalance when put together. the pedestal leg was attatched to this plate using screws and the leg stand was then fitted onto the pedestal leg. Buttons were added to the wood between there metal stand to ensure a flow between the material and the seat. the buttons really set the seat off.
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