EVO Grip

by Steven Schocher

Abstract

This research investigates topology optimisation in additive manufacturing to improve product design. The design of a 3D-printed ergonomic cable row bar demonstrates the capabilities of this emerging technology to improve performance through personalisation. This project adopts a research through practice design approach to design a 3D-printed row bar. Row bars are found in every gym today; they are traditionally made from steel with rough knurling grips that are used for heavy weights. They have poor ergonomic features when it comes to the handles, causing injury and discomfort. Topology optimisation is an algorithmic process that reveals the most efficient design based on a set of constraints or characteristics. The use of topology optimisation software will ensure the row bar is strong and functional, inspiring confidence in the user. Additive manufacturing provides a great opportunity to produce products that once were difficult to make. The use of 3D printing allows structures generated from topology optimisation to be manufactured and produced to a high quality. Taking advantage of 3D scanning will provide the ability to create completely customised handles that will improve on the current ergonomics and poor handle design of row bars. Testing these emerging technologies to create a custom row bar demonstrates that they can be used in product design to improve strength and ergonomics. This has been achieved through research, prototyping and user testing. These methods uncovered key design areas, including a test of technology, confidence in materials and added functionality. The significance of these findings has led to a well-resolved product that provides confidence in the use of topology optimisation in product design that utilises additive manufacturing and 3D scanning.

Design Intent

Topology optimisation is a developing design process that uses computer aided design to generate algorithmic solutions to remove unnecessary material while maintaining strength. The use of this technology is still being tested for the potential benefits it could bring to product design through reducing material waste and generating stronger outcomes. Topology optimisation has been heavily used in lots of engineering projects, from car parts to support structures. However, there are not many cases of this technology being used in product design, where it has the potential to completely change the way products are designed and shaped to create stronger and more sustainable products. Topology optimisation generates organic looking structures which would traditionally be hard to manufacture. The emerging technology of additive manufacturing makes this process very easy. The use of 3D printing provides the opportunity to design and create difficult geometries into high end final products that function and perform just as well as traditional methods. Topology optimisation and additive manufacturing go hand in hand to produce the best possible designs, as the difficult geometries produced by topology optimisation can be easily manufactured. Utilising these technologies, I will be redesigning a row bar used on cable machines at the gym to generate a fully 3D-printed, customised, functional product. Row bars are traditionally made from steel welded together with rough knurling on the handles for grips. There is very little ergonomic attention in the row bars designed today, as the grips are often rough and uncomfortable, causing injuries. The handles are simple cylindrical shapes that don’t offer support for your hands, or take account of any anthropometry, thus creating pain in the wrists and hands of users. With the use of additive manufacturing, I will be able to create fully customised handles through 3D scanning and 3D printing to improve the ergonomics and function of the row bar. The use of topology optimisation will also ensure that the row bar will be strong enough to support the large amounts of weight needed to perform the exercise safely while minimising the required material. These outcomes will be achieved through a research by design approach that utilises prototyping, testing, and interviews. This has helped form the design outcomes of the product through focusing on strength, material, interactions, function, and size.

Bio

I am an enthusiastic product designer who enjoys problem solving, leveraging new technologies and design principles to create innovative user-centred products. I am passionate about industrial design, UX, user-centred design and learning new technologies and ways of thinking.

I am a self-motivated product designer who works well alone or as part of a team, easy to get along with, and has great communication skills for working in group settings. I specialise in all aspects of the design process from sketching, prototyping and testing, to bringing projects to life.

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