1.
RM: Innovation
for, through, and of Extremes
By Jason Jones & David I. Wimpenny
De Montfort University
Innov_ex 09 9 May 2009

2.
Source:http://en.wikipedia.org/wiki/Gulf_war

3.
Source:www.byu.edu

4.
Source:http://en.wikipedia.org/wiki/Sugarloaf_Mountain,_Brazil

5.
RM: Innovation
J. Jones Innovex 09 9 May 2009
through,for,
Extremes
& of

6.
RM: Innovation
J. Jones Innovex 09 9 May 2009
through,
Extremes

7.
Source:http://www.notjustrocks.com/uploads/TXColmesneil8-2L.jpg

8.
Source:http://www.notjustrocks.com/uploads/120306-6L.jpg

9.
Source:http://www.notjustrocks.com/uploads/AZFlorence-1L.jpg

10.
LS
Lighting + Sand =
Fulgurite
(fulgurite.com)
Source:http://www.notjustrocks.com/uploads/AZFlorence-1L.jpg

11.
LS
Lighting + Sand =
+ Metal Powder
+ Plastic Powder
Laser
Laser Sintering (LS)
Source:http://www.notjustrocks.com/uploads/AZFlorence-1L.jpg

12.
Laser Sintering (LS or SLS)
3D Systems EOS

13.
Source:www.byu.eduSource:http://en.wikipedia.org/wiki/Amber

14.
Source:www.byu.eduSource:http://en.wikipedia.org/wiki/Amber
SLA
Stereo Lithography
Apparatus(SLA)
Sap Left for Ages

15.
Stereolithography (SLA)
3D Systems

16.
Terminology
LSSLA
FDM
3DP
SLMJetting
USC
LENS
SLS

17.
RM: Innovation
J. Jones Innovex 09 9 May 2009
through,for,
Extremes
& of

18.
RM: Innovation
J. Jones Innovex 09 9 May 2009
for,
Extremes
& of

19.
Source:www.carpentertrade.com/ordering.html;en.wikipedia.org/wiki/Grip_(gymnastics)

20.
Source:ducati.com

21.
• Pressure a helmet exerts on the head
Correct helmet Small helmet Customized
helmet

22.
What is Custom-Fit?
is:
• A Paradigm where
• Digital Manufacturing is
• Driven by Customer Data in order to
• Produce Customised Products for their Body

23.
What are you going to change?
Customised liner
Padding
EPS

24.
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
Source:Custom-fit.org

25.
3D scanning

26.
Automated design

27.
30/01/2015
Result

28.
30/01/2015
Growing Wish List

29.
(Results: failure. HIC = 2460; peak = 280G)

30.
The Next Generation

31.
The customer is always right.
Source:Ducati.com/LoughboroughUniversity

32.
Customer feedback
92% of the motorcyclists
surveyed feel discomfort from the seat
when travelling long distances
Source:Ducati.com/LoughboroughUniversity

33.
• 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 Body
Geometry
Customer feedback
Source:Ducati.com/LoughboroughUniversity

34.
• 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
Source:Ducati.com/LoughboroughUniversity

35.
What part(s) to change?
Stability
Pad (inside)
Comfort
Aesthetics
Cover (sky)
Bottom
Cover (sky)

36.
How to meet customer need?
• What bike part(s) to change?
– The Seat
• How to drive the changes?
• What changes to make?
Source:Ducati.com

37.
How to drive the changes?
• Unsuccessful attempts:
Scanning Measuring
Source:Human-solutions.com(farleft)

38.
• Success: Empirical data from Pressure Map
How to drive the changes?

39.
How to drive the changes?
• What about subjective data (your feelings)?
Source:IBV
Emperical Data
(mm Hg)
Subjective Data
(Feelings)+
Hybrid Data
(Comfort Map)=

40.
How to drive the changes?

41.
How to drive the changes?

42.
How to drive the changes?

43.
How to drive the changes?

44.
How to drive the changes?
Zone 3
Zone 2
Zone 1

45.
How to meet customer need?
• What part(s) to change?
– The Seat
• How to drive the changes?
– Empirical + Subjective Data
• What changes to make?
Source:Ducati.com

46.
What changes to make?
• Laboratory Stiffness testing:
– Establish the dynamic performance of the
standard seat material (benchmark)
– Explore the performance of alternative materials

47.
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.

48.
What changes to make?
• Using CAD & Computer Analysis (FEA):
– Make an array of the “spring” like structures
– Insert them into the seat according to…

49.
What changes to make?
• …the customer defined Comfort Zones with
the customer specified stiffness

50.
What changes to make?
• Customised Seat making application

51.
• Customised Seat making application

52.
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
Source:Ducati.com

53.
The virtual result

54.
The virtual result

55.
The virtual result

56.
Digital fabrication
• Validated design using: Laser Sintering
3D Systems EOS

57.
The result

58.
Ducati seat
Top side Under side

59.
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?

60.
RM: Innovation
J. Jones Innovex 09 9 May 2009
through,for,
Extremes
& of