Design and engineer a battery-powered electro-mechanical device that addresses unmet user needs for an underserved group while maintaining broad consumer appeal. The project spans user research and concept generation through to DFMA optimisation, detailed 3D CAD modelling, and a fully functional prototype.
Focus
Industrial Design Engineering · DFMA · FEA
Timeline
18 Weeks · 2026
Toolkit
Overleaf · ANSYS (FEA & CFD) · 3D Printing
Final Design (CardClutch):
Main Roles (Chief Information Officer):
Process Architecture & Documentation:
Outlined the end-to-end project workflow and logic from the initial research phase through to writing and producing the technical report submission.
Engineering Validation & Simulation:
Applied validation methodologies and ran technical analysis throughout the design process, including mathematical modelling, ANSYS FEA, Boothroyd-Dewhurst DFMA assessments, and injection moulding simulations.
Design Iteration & Standards Compliance:
Translated simulation results into actionable parameters for the team (e.g., using FEA to guide structural rib placement) while ensuring product labelling and safety complied with ISO, UK, and EU regulations.
The Process: Double Diamond Framework
Discover
Researched users, competitors, and existing solutions to identify opportunities and evaluate four initial concepts.
Define
Used a weighted decision matrix and user feedback to select the concept and establish its engineering requirements.
Develop
Iteratively developed the measuring, cutting, and guidance subsystems through CAD, prototyping, testing, and refinement.
Deliver
Integrated the final system before refining its DFMA, CMF, branding, compliance, and packaging.
Key DFMA Factors
Uniform Walls & Ribbing: Maintained consistent wall thickness with 1.5 mm ribs and optimised corner radii to minimise sink marks and improve mould release.
Draft Angles: Applied 1° draft to vertical faces and 0.5° to ribs to enable reliable part ejection and reduce mould wear.
Poka-Yoke Assembly: Used chamfers, locating pins and asymmetric shells to guide assembly and reduce error.
Standardised Fastening: Used 20 mm M3 thread-forming screws, achieving 7.6 kN retention while reducing fastener variety.
FEA-Validated Snap-Fits: Designed tapered cantilever snap-fits with an assembly stress of 46.4 MPa, well below the 139 MPa yield strength of PA6-GF30.
Vibration & Resonance Control: Achieved a 211 Hz casing natural frequency, separating it from the 400 Hz motor excitation and the 10.9–17.3 Hz hand-arm vibration range identified in ISO 5349-1.
Additional Validation
Collaborations & Stakeholders
