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Tyvek Tool Caddy – Waste Stream Product

The tool caddy stores worksite hand tools using waste Tyvek sheets commonly found on construction sites.
3 Week Project as part of the Other Today Studio at University of Brighton 2nd Product Design
What have I done?
  • My project began with an interest in using a textile as the sheet material. Early on I focused on fabrics such as canvas for use in a wallet or similar application. While exploring materials, I came across ‘Mighty Wallet’; a wallet made from a Tyvek envelope. I often see Tyvek in skips so decided to research Tyvek further. Several people online have used the material for tote bags, drawstring bags and the like, however this is from virgin rolls of tyvek not offcuts. Tyvek do offer a recycling system for its products but it is highly inaccessible and offers no benefits to the construction companies.
  • This is my supply chain intercept point, providing an alternative to throwing away the material into skips. I could either remove the waste Tyvek from skips when they get sorted after collection, or work with the construction companies to set aside the Tyvek scraps to be sent via post as a bundle would be quite light. Alternatively a local rep could collect offcuts from several worksites and send it to the manufacturer in a larger bundle. This would save them money from skips costs and prevent this useful material from entering the landfill.
  • I wanted the product to stick to the materials origins as much as possible, ensuring that the product didn’t have far to be sold, so I focused on something for the worksite, such as tool storage. Storing tools on a worksite in a well organised manner is essential to an efficient building process so I saw producing a strong bag to hold the essentials from an inexpensive material as an opportunity.
  • Research into origami and different folding methods for paper worked well for finding the strongest and most space efficient storage method. The traditional method of producing pockets uses oddly shaped material and leaves the material proud which can catch and tear on worksite obstructions when not being used. The origami folds I used keeps the pockets flat when not being used.
  • Leaving it with a clean aesthetic was important such as hiding the stitches, but the strength of the joints was paramount, where these folds came into play. I also has very little waste and fold into itself to ship as its own envelope.
Research

Material Research Ended in Tyvek being chosen as the material to be used, and further research such as stitch length and thread tension was done to ensure the best project was made.

Tyvek Supply Chain

Iteration

Several iterations were made in terms of folds and interactions between the materials. Origami techniques were changed and altered from standard variations.
As I was originally going to do a wallet, some of the folds I used there could have been used in my final object.
The coin wallet was a good test, in terms of strength and the types of folds that can be used.
Both tyvek and paper were used for the testing of these folds.
Instructions for Manufacture
Below is the cut and fold list for the entire tool caddy. Depending the whether the end user or the manufacturer is making the caddy. It can be either hand sewn or machine sewn, which ever is avaliable.
30 x 150
  1. Knife pleat fold at 50mm and 25mm
  2. Repeat once
400 x 130
  1. Knife pleat fold at 50mm and 25mm
  2. Repeat 4 times
  3. Vertical fold at 100mm
160 x 230
  1. Knife pleat fold at 65mm and 30mm
  2. Knife pleat fold at 125mm and 15mm
  3. Vertical fold at 130mm
100 x 240
  1. Knife pleat fold at 40mm and 20mm
  2. Repeat three times
740 x 80
  1. Fold in half lengthways
600 x 420
  1. Fold in half lengthways to make 600 x 210
  2. Crease every 73mm
  3. Fold vertically 10mm at the open end of long edge
  4. Cut 10mm at 73mm creases where vertical fold has been made
Final Product
Final Product as posted on the left and as assembled on the right
Potential in the project
  • I found the material quite nice to sew and cut as it is very much like paper. It’s easy to cut square and fold in the right places. I see a lot of potential in other products that could be made with the material, from smaller items such as a safety glasses case, or stuff sacks for waterproof clothing to an entire storage rack for a van or digger. Very specific tool kits for jobs could be made in the material as tool rolls, such as a daily maintenance kit for an excavator.
  • The main benefits of using this material are of course the interception of a waste stream, with very standard sizes of offcuts. They are almost always full width offcuts, and therefore designs can easily be made parametrically according the the length of offcuts.
  • Since the material can be laser cut means these parametric designs can be simply cut out without any complications, depending on the material available.
  • Changes to the current design would include making it entirely machine sewable and placing a solid bottom into the caddy to make it more stable (although this isn’t within the brief).

Research Appendix

Fabric Land Brighton
Kraft Paper Wallets
Strong card leading on from the paper wallets
There are bitumen sandwiched by a layer of card on each side, which is quite strong due to the paper and waterproof due to the bitumen.
Tyvek Wallets
Started making wallets from one tyvek envelope as a DIY project without having to sew anything together and was easily customisable as users can just draw on their wallet.
A polyester based material used for wrapping houses to keep the moisture out
Could be an offcut based product, using scraps from construction sites to produce wallets as and when they have enough material.
Plenty of scraps in skips.
Tyvek Sewing
Main outcomes of this were sewing details which are covered on the hand written A3 sheet
Origami book
Folding Techniques for Designers: From Sheet to Form – Book by Paul Jackson
Research regarding types of fold to create the tool pockets was essential and this book helped me focus in on certain types of folds. The final fold concept was the knife pleat which I adapted to be a pocket.
Draft Supply Chain
Cut Layouts
Image links
Skip –
Wallet –
Messy Tools –
Toolroll –
Origami –
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Land Rover Project

Various modifications and improvements made to my Land Rover either in progress or completed.

Summer 2018

Swapping Springs for the front of the Land Rover.

The previous owner put the wrong springs on each side when he restored the vehicle, causing the vehicle to lean to one side as the springs are sided. The springs were taken on and swapped, with a small repair done and a de-rust and oil to improve the ride of the car.



Christmas 2018

The Project over Christmas was to restore the dashboard of the car. Since this is where the driver sits 95% of the time it is nice to have a well covered and good looking area to drive from. In the process of the physical restoration of the dashboard, I restored the gauges, trim and heater matrix of the vehicle. The main dash pieces were fairly rusty and required lots of welding, which was quite difficult due to how thin the steel was!The first section was about renewing the metal by welding sheet steel after bending into the space which was left after cutting out the rusted metal.




As part of the dashboard remake, the wiring needed a lot of attention. This stage I got the lights working properly and added a relay to them, which made them brighter and reduced the chance of a fire in the cab, and the high voltage didn’t travel through the dashboard.

Here are the recondition gauges which were rather difficult to get the bezels and glass back into.

This is some of the wiring in the engine bay which the previous owner did. Rather shoddy and was replaced by adding new connectors and cleaning it up.
Below is the trailer hitch which was causing a lot of problems as it wasn’t wired properly. This was ignored until all the wiring was working and then was simply spliced into the new wiring.

Heater Matrix and Fan

The existing fan was shot – Spending £100 for a new motor was a no go at that point, especially since fans from Mini Coopers were £12 and blow better and faster. All the original mountings were used and so an original motor could be used in the future if required.



Using kitchen extractor pipe also saved some money which could be better spent on other parts of the project (£80 for a short section was again ridiculous). The heater core was reused after a good flush and clean up and paint of the box.

Learning about the resistor and switch mechanism was interesting and that something that simple could be used the control the speed of the fan.

I did of course take apart the motor to see how it worked and if it could have been saved.

Rims

No fancy alloys for me thank goodness. Good old steel rims. A lot of angle grinding and old paint and rust and they were ready to paint. Red oxide and then some hand painted 2k limestone and they were ready to go. Just a day to mount the tyres before the Claygate Flower Show classic car event.

Classic Car Show

It was very nice to set up next to some amazing classic cars and have so many people come and talk to me about their experiences with Land Rover and the good memories that they still remember from their childhoods.

Clutch Bearing…….or mainshaft bearing……or both?

The noise was more of an irritant that a problem, according to the haynes manual.

Using an endoscope I tried to diagnose the clutch bearing but it seemed all good. The mainshaft of the transmission was the next culprit and therefore it was decided to take of the hub at the back. Again everything was fine and was left after replacing the spring clip and lock nut at the end of the mainshaft.

Seating for the rear

It is rather uncomfortable in the back especially without seats. Rather than buying them I decided I could make a higher quality seat for less money and it would also fit much better.

It it to be mounted to the rails n the side and would be a single cushion on the back two benches.

Still a work in progress but they will be covered in the same material as the dashboard, with a stockinette underneath.

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Arduino – Week 4 – Robot

The final week task was to program a robot which would move by itself and avoid objects

Unfortunately this wasn’t completed due to time constraints, although most of the code for the movements was completed and fully working

The board was attached to the chassis with metal standoff – which did short the board out – however it was sorted out by replacing them with plastic ones

Two stepper motors were used to control the robot, one on each side.

There is a breakout board on top of the arduino, which allows for easy plugging in and out of the stepper motors

Coding

Below is the coding used for the control

Where the breaks are for the left, right, forward, and reverse, the position of the output pins have been changed, so that the stepper motor activated the different magnets in a different order, which changes the direciton.

The left and right have one wheel going forward and one going backwards, therefore turning on the spot, similar to how tanks rotate using their tracks

Here the robot is programmed to run the command for about 16 seconds, after which it will stop moving

/*
  Stepper Motor lakelly 02/05/2019
*/

// the setup function runs once when you press reset or power the board
void setup() 
{
  // initialize digital coil A as an output.
  pinMode(10, OUTPUT);
    // initialize digital coil B as an output.
  pinMode(11, OUTPUT);
    // initialize digital coil C as an output.
  pinMode(12, OUTPUT);
    // initialize digital coil D as an output.
  pinMode(13, OUTPUT);
  //motor 2
  pinMode(6, OUTPUT);
    // initialize digital coil B as an output.
  pinMode(7, OUTPUT);
    // initialize digital coil C as an output.
  pinMode(8, OUTPUT);
    // initialize digital coil D as an output.
  pinMode(9, OUTPUT);

}

 int i=0;
  
void loop() {

   while(i < 1000){
  right();
  i++;

   }
}

void forward()    //+++++++++++++++++++++++++++++++++++++++++++++++FOWARDS++++++++++++++++++++++++++++++++++++++++++++++
{
      //STEP 1
  digitalWrite(10, HIGH);   
  digitalWrite(11, LOW);   
  digitalWrite(12, LOW);
  digitalWrite(13, HIGH);
  delay(2);                      // delay
      //STEP 2
  digitalWrite(10, HIGH);   
  digitalWrite(11, HIGH);   
  digitalWrite(12, LOW);
  digitalWrite(13, LOW);
    delay(2);                      // delay
      //STEP 3
  digitalWrite(10, LOW);   
  digitalWrite(11, HIGH);   
  digitalWrite(12, HIGH);
  digitalWrite(13, LOW);
    delay(2);                      // delay
      //STEP 4
  digitalWrite(10, LOW);   
  digitalWrite(11, LOW);   
  digitalWrite(12, HIGH);
  digitalWrite(13, HIGH);
    delay(2);                      // delay

//motor2
  //STEP 1
  digitalWrite(6, HIGH);   
  digitalWrite(7, LOW);   
  digitalWrite(8, LOW);
  digitalWrite(9, HIGH);
  delay(2);                      // delay
      //STEP 2
  digitalWrite(6, HIGH);   
  digitalWrite(7, HIGH);   
  digitalWrite(8, LOW);
  digitalWrite(9, LOW);
    delay(2);                      // delay
      //STEP 3
  digitalWrite(6, LOW);   
  digitalWrite(7, HIGH);   
  digitalWrite(8, HIGH);
  digitalWrite(9, LOW);
    delay(2);                      // delay
      //STEP 4
  digitalWrite(6, LOW);   
  digitalWrite(7, LOW);   
  digitalWrite(8, HIGH);
  digitalWrite(9, HIGH);
    delay(2);  // delay
}

void backward()    //+++++++++++++++++++++++++++++++++++++++++++++++BACKWARDS++++++++++++++++++++++++++++++++++++++++++++++
{
  //STEP 1
  digitalWrite(10, HIGH);   
  digitalWrite(11, LOW);   
  digitalWrite(12, LOW);
  digitalWrite(13, HIGH);
  delay(2);                      // delay
      //STEP 2
  digitalWrite(10, HIGH);   
  digitalWrite(11, HIGH);   
  digitalWrite(12, LOW);
  digitalWrite(13, LOW);
    delay(2);                      // delay
      //STEP 3
  digitalWrite(10, LOW);   
  digitalWrite(11, HIGH);   
  digitalWrite(12, HIGH);
  digitalWrite(13, LOW);
    delay(2);                      // delay
      //STEP 4
  digitalWrite(10, LOW);   
  digitalWrite(11, LOW);   
  digitalWrite(12, HIGH);
  digitalWrite(13, HIGH);
    delay(2);                      // delay


//motor2
  //STEP 1
  digitalWrite(9, HIGH);   
  digitalWrite(8, LOW);   
  digitalWrite(7, LOW);
  digitalWrite(6, HIGH);
  delay(2);                      // delay
      //STEP 2
  digitalWrite(9, HIGH);   
  digitalWrite(8, HIGH);   
  digitalWrite(7, LOW);
  digitalWrite(6, LOW);
    delay(2);                      // delay
      //STEP 3
  digitalWrite(9, LOW);   
  digitalWrite(8, HIGH);   
  digitalWrite(7, HIGH);
  digitalWrite(6, LOW);
    delay(2);                      // delay
      //STEP 4
  digitalWrite(9, LOW);   
  digitalWrite(8, LOW);   
  digitalWrite(7, HIGH);
  digitalWrite(6, HIGH);
    delay(2);                      // delay
}


void right()  //+++++++++++++++++++++++++++++++++++++++++++++++RIGHT++++++++++++++++++++++++++++++++++++++++++++++
{
   //STEP 1
  digitalWrite(13, HIGH);   
  digitalWrite(12, LOW);   
  digitalWrite(11, LOW);
  digitalWrite(10, HIGH);
  delay(2);                      // delay
      //STEP 2
  digitalWrite(13, HIGH);   
  digitalWrite(12, HIGH);   
  digitalWrite(11, LOW);
  digitalWrite(10, LOW);
    delay(2);                      // delay
      //STEP 3
  digitalWrite(13, LOW);   
  digitalWrite(12, HIGH);   
  digitalWrite(11, HIGH);
  digitalWrite(10, LOW);
    delay(2);                      // delay
      //STEP 4
  digitalWrite(13, LOW);   
  digitalWrite(12, LOW);   
  digitalWrite(11, HIGH);
  digitalWrite(10, HIGH);
    delay(2);                      // delay


//motor2
  //STEP 1
  digitalWrite(9, HIGH);   
  digitalWrite(8, LOW);   
  digitalWrite(7, LOW);
  digitalWrite(6, HIGH);
  delay(2);                      // delay
      //STEP 2
  digitalWrite(9, HIGH);   
  digitalWrite(8, HIGH);   
  digitalWrite(7, LOW);
  digitalWrite(6, LOW);
    delay(2);                      // delay
      //STEP 3
  digitalWrite(9, LOW);   
  digitalWrite(8, HIGH);   
  digitalWrite(7, HIGH);
  digitalWrite(6, LOW);
    delay(2);                      // delay
      //STEP 4
  digitalWrite(9, LOW);   
  digitalWrite(8, LOW);   
  digitalWrite(7, HIGH);
  digitalWrite(6, HIGH);
    delay(2);                      // delay
}


void left()   //+++++++++++++++++++++++++++++++++++++++++++++++left++++++++++++++++++++++++++++++++++++++++++++++
{
 //STEP 1
  digitalWrite(10, HIGH);   
  digitalWrite(11, LOW);   
  digitalWrite(12, LOW);
  digitalWrite(13, HIGH);
  delay(2);                      // delay
      //STEP 2
  digitalWrite(10, HIGH);   
  digitalWrite(11, HIGH);   
  digitalWrite(12, LOW);
  digitalWrite(13, LOW);
    delay(2);                      // delay
      //STEP 3
  digitalWrite(10, LOW);   
  digitalWrite(11, HIGH);   
  digitalWrite(12, HIGH);
  digitalWrite(13, LOW);
    delay(2);                      // delay
      //STEP 4
  digitalWrite(10, LOW);   
  digitalWrite(11, LOW);   
  digitalWrite(12, HIGH);
  digitalWrite(13, HIGH);
    delay(2);                      // delay


//motor2
  //STEP 1
  digitalWrite(6, HIGH);   
  digitalWrite(7, LOW);   
  digitalWrite(8, LOW);
  digitalWrite(9, HIGH);
  delay(2);                      // delay
      //STEP 2
  digitalWrite(6, HIGH);   
  digitalWrite(7, HIGH);   
  digitalWrite(8, LOW);
  digitalWrite(9, LOW);
    delay(2);                      // delay
      //STEP 3
  digitalWrite(6, LOW);   
  digitalWrite(7, HIGH);   
  digitalWrite(8, HIGH);
  digitalWrite(9, LOW);
    delay(2);                      // delay
      //STEP 4
  digitalWrite(6, LOW);   
  digitalWrite(7, LOW);   
  digitalWrite(8, HIGH);
  digitalWrite(9, HIGH);
    delay(2);                      // delay
}
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Dice making Fusion 360

Making the dice is about learning Fusion 360 and using as many different techniques as possible

My original method is as follows:

Sketch 10×10 square > Extrude up 10mm > draw on dots by either using the pattern tool and deleting the extras or using the construction line at a diagonal and making equal circles on that line > extruding all circles on each sketch individually by -0.5mm > filleting edges to 1mm radius

Steps which I found difficult – creating 10x10mm square at start > I would type in 10mm and then click enter as i’m used to rhino and need to do that to define the next dimension rather than tab

made a few mistakes by not clicking on commands or getting mixed up by still being in a command and trying to get into a new command

long winded process of creating a different set of circles for each face could be improved > possibly by using a pattern then copying it to each face

Storage location for all recordings : Autodesk Screencast

Strengths:

Professional looking free software which has similar capabilities as Solidworks

Can change some settings to be the same as solidworks

Weaknesses:

Another software to learn with different shortcuts

Opportunities:

Being able to use another CAD software  > Increases Employability

Threats:

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