My Semester with Digital Making

Expectations

When entering this course I truly had no idea what to expect. I had been advised by my fellow classmate that heard that this was an interesting course to take our senior year. Although I didn’t know what we were going to be doing in the class I did know that I have yet to take a class in college anything like it. Throughout my college career, I had been taking very limited classes with a very structured view of business. This course offered me a great opportunity to work on the making behind the business plans, which is what really intrigued me to sign up!

Fusion360 and 3D Printing

As a business major coming from the Gies College of Business, I came into this course with really no background in any design program. Although the course was a huge learning curve I have definitely gained some pretty valuable skills in the process. This first program we learned was Fusion360. This was such an amazing experience because we really got to learn and visualize our designs and then print them on the very same day. I have many aspirations to create my own company and learning the skill of prototyping while utilizing a program like Fusion 360 is definitely going to benefit me.

Iterating

Throughout our entire process, we worked tirelessly making our project as great as it could possibly be. As a group, we met on many occasions in the Art and Design Building making improvements to our prototypes. Again coming from the business school we really haven’t been able to create build and foster projects as we did in this class. I really found great pleasure in working with our projects and learning about the idea of iteration. Throughout our project, we went through 5 or 6 separate prototypes and a large make-a-thon where we put all our hard work together. We went from prototypes made out of paper to cardboard to bending acrylic. This is a process that takes time and effort and is extremely rewarding in the end.

InkScape and LaserCutting

Also in the semester, we got very personal with the FabLab which is an amazing building by the ACES library that has such an incredible environment that foster ingenuity. With the FabLab We worked on making a watch and the great staff members really helped us to understand the software and hardware involved. We needed to work on our software skills so we could design the watch. That is when we were introduced to InkScape. InkScape is a program the allows us to model our prints in 2D instead of 3D. This is important because for the laser cutters that we would be using in the FabLab we need to be able to model in 2D for the cutters to understand. After a quick tutorial on the basics of InkScape we were tasked on creating our watch face so the user would be able to know if the watch function was set to measure “twists” or “curls”.

Overall I have a fantastic time joining this class. I have never been in a class where I have been able to interact and physically design solution for issues that people face every day. One of my favorite thing Professor Vishal said day one was, “We are not looking to solve problems, but we are looking to find opportunities”. I thought that this was an amazing way to look at innovation that I have never noticed before.

Team 2: Movi Final Project Reflections

Introduction

Hello everybody, we are team Movi! As a group this semester we came together in Professor Vishal’s BADM 357 Digital Making Seminar to combine our individual talents to come to a common goal of trying to make a difference. This semester we paired with Disability Resource and Educations Services (DRES) to work on finding opportunities where we could make a change. This was a phenomenal experience and opportunity for all of us to make a hopefully lasting impact on our community.

Our Mentor: Jenna Fessemyer

Jenna Fessemyer

Back in the first week of our course, we were happy enough to meet Jenna. Jenna is a current RA at Newman Hall and a senior studying Kinesiology here at the University of Illinois. Jenna has also been using a prosthetic leg her entire life. But oh boy that only fueled her to do more amazing things. Jenna is an avid runner and athlete who just one week ago complete the Boston Marathon. She first sparked our interest when she began to explain her story about her prosthetic leg. In our first meeting, Jenna explained how she has always had trouble walking in the wintery conditions that Champaign Illinois is accustom to for 5 months a year. She went on to explain that even though her prothetic C-leg is worth upwards of $100,000 she is still trained to fall on that leg. With that information, we were baffled to hear that even though her leg is so valuable and she is taught to fall on it in a crisis, there were not many options within the market. After that first day and meeting how amazing of a person Jenna was we were determined to make a difference.

Research

Our group first looked into the market of different prosthetic leg protection types. This helped us brainstorm different ideas and helped us examine the possible impact of our project. We also looked in the different materials and machines that are already available in the market. The first product that we looked into was Jenna’s current leg protection cover, the “Ottobock C-Leg Cover”. This leg protection was very bulky and was not very flexible due to its hard material, silicone. The other protections had a very slim pad of silipos gel. And it only covered the knee portion for Jenna.

Our group quickly realized that these leg protections have a lot of flaws and needed improvement. We were lucky to interview Jenna through this process and Jenna gave us some great insights. First, she told us that the “Ottobock C-Leg cover” can be improved by making the overall product less bulky, especially the back part where all the mechanism is located. Because the leg protection is too bulky in the back, she cannot bend her leg all the backward. With the silipos gel leg protection, Jenna also told us that she does not need protection above her knee. This product will actually hinder her from running and will not actually protect her expensive C-Leg. Lastly, Jenna complained about how the design is too bland. This made her neglect her form using prosthetic leg protections. She wanted to feel special and told us that she will feel more obligated to wear the prosthetic leg if the leg was designed to fit her style.

Prototyping

We thought the design process was going to be easy. However, we were wrong. At first, we went into the process blindly without knowing what our user, Jenna, wants. We tried to come up with our own designs and made prototypes based on the designs we came up with. And we quickly realized that those designs are similar to the volleyball knee pads in the current market. We tried to focus on the knee since it’s the most protruded out portion of the human anatomy. And we assumed that is the portion that needs the most protection. But after our meeting with Jenna, we quickly realized that this design challenge is much different than we first anticipated. We were testing our prototypes for the wrong user and we quickly scrapped the first prototypes.

Jenna showed us her C-Leg model and told us a few key points she wants in her design. She did not like the connection going around the back of her knee, because there is a lot of mechanisms that should not be disturbed. And she does not need any protection above her knee due to it limiting her movement. She also does not need bulky protection around her knee, because she only wants to protect her C-Leg since it’s a hundred thousand dollars. She also wanted the protection to cover her top and the side portion of the C-Leg. This is where most contact happens when Jenna falls on her C-Leg. Lastly, Jenna wanted the prosthetic leg protection to be able to easily attach and detach to her C-Leg.

With Jenna’s amazing insights and understanding of the market, we started brainstorming some ideations. We decided to make the straps come behind the leg protection, but it will not be in the way of the C-Leg mechanisms. Then we decided to use a hinge to easily attach and detach the prosthetic leg protection. With these insights in mind, we made two separate prototypes that illustrate our thought process. Now the C-Leg protection will protect the top and side part of the C-Leg and will not go all the way around the back of the C-Leg. This will make the overall design less bulky. Then the design will have a hinge for easy attach and detachment. Finally, the design cover can be customizable according to the user’s needs.

Overall, we wanted our product to be simple and slim compared to the old “Ottobock C-Leg cover”. Since we cannot have Jenna fall over every single time we make a new prototype, we needed to constantly ask her for improvements and refinements of the prototypes. I think the shin guard gave us a lot of inspiration. She shin guard only protects the shin and the side parts of the leg. So, we tried to follow it’s mechanism, but also fit the C-Leg. And most importantly, we wanted to create a protection that can be customizable according to the user’s preference.

Make-A-Thon

Step 1: We found it very helpful to make a 3D scan of the individual C-Leg. We used a scanner app to convert the image to a .stl file. Our mentor was out of town during our prototyping session so we 3D printer her scanned leg to use for her prototype. Even if you plan to prototype on your own leg, it still will be helpful to scan your leg if you plan on 3D printing because you can build your model design on the actual contours of the scan.

Step 2: We decided to use Acrylic and utilized inkScape to help shape and cut our design. After our design was cut we used a heat gun provided by the fab lab to mold the acrylic to the shape of our 3D printed model of the C-Leg

Step 3: We created the inner padding by using styrofoam and sheets of metal to hole shape to fit inside the acrylic. After the padding was complete we used our tough nylon to create a cloth outer coating and straps to help secure it.

Step 4: We split our acrylic down the middle and added a hinge to make the design easier to put on and simple to take off.

Step 5: Final steps of making everything fit together and ensuring it was up to the standards of safety we had set. At the end of the weekend, we were very happy with what we had put together.

Post Make-A-Thon

After we won the judgment portion of Make-A-Thon we were very excited to continue with our idea for the remainder of the semester. The next week we were able to meet up again with Jenna, our mentor, and do some testing. Overall, the testing went great. We had followed the testing protocol that we had constructed a couple of weeks earlier and were able to work with Jenna. She really liked the way we incorporated different materials and really thought our design was super cool and represented her personality well. There were also definitely areas we needed to improve. The 2 areas that we could improve were to make the interior less slick so the guard would stay secured on and use a more flexible exterior material and make the design less bulky.

The next week we came back to the Art and Design Building and kept working on additional prototypes. To address the bulkiness we took out the interior padding and wanted to change it to silipos gel. Then finally to address the concern of the slickness of the pad we painted the inner nylon layer with a plastic dip which we believed to create more friction between the nylon and the metal part of Jenna’s calf.

Moving Forward

Even though the semester is over, our project will continue forward. We shared our plans on how we are going to take this further if we have more time. For example, we wanted to test our prototypes with more users. Jenna and Jeannette have been our great users throughout this process. However we learned from this class that everyone has their own opinions and the more user group, the stronger our project will become. For instance, every age group has their own opinion for certain designs. Jeannette wanted a huge padding on top of her C-Leg, whereas Jenna wanted minimal padding on top of her C-Leg. They had to do due to each group age’s daily routine and how often they fall on their prosthetic leg.

Next, we wanted to manufacture for a larger group. We were thinking about partnering with prosthetic leg companies to figure out the different scale of each prosthetic leg. This will give us a general database of how big we should make our prosthetic leg protection. We can maybe narrow down the prosthetic leg protection size into five different sizes.

Ultimately, we want to meet with our users one on one and ask them questions to create a prosthetic leg protection that is for that specific user. We will need to coordinate the size of the prosthetic leg, the color of the prosthetic leg protection, the overall design of the prosthetic leg protection. This may cost more time and effort, but overall it is worth the investment.

Final Presentations Slides

Make-A-Thon

I believe that this was such an amazing experience to see and work on as a group. We put in tons of hours to get our product up and running and it felt so gratifying to come out with a product we were happy with!

Initially, we started with a plan to work by making a 1:1 replica of Jenna’s leg. With this, it was really such a huge help to propel our ideas forward. From there we worked on constructing our pad, outer shell, and designs.

When constructing our pad we used 2 pieces of Styrofoam padding with strips of metal on the inside to help with structure and security. After we created the interior lining of the pad we wanted to sew a nylon fabric around it to give it a better aesthetic appeal.

After our pad was complete we began working on shaping our outer shell and design to lay on it. Jae made so many fantastic designs so after we had our shape laser cut out of acrylic we were able to laser cut Jae’s design into it. After our piece was designed we were able to use the heat gun provided by the FabLab and mold our design to Jenna’s model leg we had. After we had the shape we cut our shell down the middle and attached a hinge to make it simple for Jenna to attach the guard. Final we attached the pads and traps we had made to the design to complete the final touches.

Overall this experience was amazing to work with and around such fantastic people that all had a common goal to make the world a better and easier place with their designs. After our presentations were put together and the judging was over with me and my team had been lucky enough to be named one of the winners of the competitions! Thank you to the school of design and school of business for coming together and making this happen. Im am so happy I got to experience something like this before I graduate.

Week 11- Meeting with Milestone and Materials Selection

Guest Speaker- iVenture

To begin class this week we had a guest speaker from the University of Illinois iVenture program. The iVenture program is organized by the university to better help student with new business ideas collaborate to make them a reality. iVenture provides grants and scholarships up to $10,000 to help these projects succeed. It sounded incredibly intriguing but as I am a Senior graduation this spring it sadly doesn’t apply to me.

Meeting with Milestone Labs

Our meeting with Milestone Labs I feel as if went pretty well. We showed them our prototype ideas and testing protocol. My team, Movi, has been working a lot with Jenna in creating our prototypes. We showed them our new concept of having the guard be secured by hooks on the back and the knee pad on the front. After we walked them to our 3rd and 4th round prototypes, I walked them through our testing protocol. This was cool to walk the consultants through because they could see our high-level thought process when conducting our testing.

Project Update/Materials Selection

After our meeting with Milestone Labs, our group came together to begin the process of our mood board as well as select materials that we need for Make-a-thon. First we started working on all of our ideas to put on the mood board. Jae has always done a fantastic job showing his design skill, but now it was Nathan and mine turn to help him out. We all took about 10-20 minutes drawing prototype ideas of how we should move forward. In my design I wanted to work off of our current iterations. In my design, I added a snap hook feature as well as material ideas for the entire design.

When selecting materials it was really important for us to include everything we might need. We took our process piece by piece in our designs to make sure we didn’t miss anything. Thanks to Nathan, who met with his material science professor, we had an idea of some materials we should be looking at. For example when selecting a material for our knee pad we bough a bike helmet. Bike helmets are made of light weight high impact foam which we though would be prefect for our design. Below is a list of ideas and materials we decided to buy:

Design prototype made in class
  • Inner liner protection- Silicone Caulk
  • Knee Pad- High impact foam (bike helmet)
  • Attachment- Velcro, Metal Hooks, Small snap hooks
  • Scratch Resistant- Plastic Dip/Spray (Various colors), Nylon sleeve
  • Outside Hardshell- Plastic sheet (provided)

As seen from our list, we wanted to think our features we wanted and decided the materials to help us get it there. I am genuinely excited to jump into Make-a-Thon next weekend and make our officially usable prototype. Before we get there our group has a couple of task we need to get done so we can get right to making at Make-a-Thon. The first thing we want to complete is our mood board. We are collaborating by trying to make 3 designs by the end of this week each to put on the board. Secondly, we need to have scans of Jenna’s leg so we can begin working in CAD for measurements. Finally, Jae has been working with Jenna to identify stress points on her leg when she falls. These are really important for us to know when designing our prototypes so we can understand what parts of the guard we should pay more attention too.

Week 10- Preparation For Make-A-Thon

Make-A-Thon Prep

This week was a little different from most. Sadly, I wasn’t able to attend class due to our meeting time changing for a Pre Make-A-Thon Session. From reading my other classmates posts and knowing what we did in class it seemed incredibly beneficial. I was unable to attend due to a time conflict with my other class. I attached some photos here of the sessions that some of my classmates added to the forum already.

Movi Project Update

After coming back from spring break it was great that Professor Vishal assigned us an assignment that could put our team back on track. This week our group met up in the Business Instructional Facility to discuss our testing protocols for our project. Our group went very in-depth on how we should go about testing our product. It was really great to discuss with both Jay and Nathan about this because moving into Make-A-Thon next weekend we need to understand how and why we need to test our product. I think our entire group is really excited to get into Make-A-Thon to start creating and making our project a reality. With the major number of mentors there to help us with ideas and testing, I’m excited to get our feet on the ground and start MOVIng.

Week 9 Recap- Putting it all together

This week was really cool because we were able to put our projects together that we have been working on the past couple weeks in the FabLab.

Physical Therapy Watch

The physical therapy watch that we have been working on the last couple of weeks is intended to patients correctly measure the effectiveness of their exercises. Utilizing tilt sensors and adjustable curl and twist settings this watch allows outpatients to better understand if they are correctly maximizing their workouts.

To begin we had to come to class with our laser cut watch face so we wouldn’t have to wast class time printing everybody’s out. This turned out to be incredibly beneficial because we were very pressed for time. When we arrived we were handed the remaining pieces of our watch along with come kits so we can integrate the sensor technology into our designs of our watch.

These kits were our biggest learning experience of the day because they helped us learn how to run code to our circuit boards to teach them different operations. To help operate the program we utilized a program named Arduino to input our designated codes into the circuits. It was really awesome to see that we were able to completely put together the entire product all the way down to the code telling the board what to do. This was the number one reason a lot of us joined this class and I believe to be the biggest value. We are learning ways to interact with technology to make things to better our society. The purpose of our code was to connect the board with the sensors to communicate when to register a correct movement or not, whether that be a curl or twist. With a combination of our watch face to help tell the users if they were work a twist or curl the code worked great.

After the coding of our circuit board was completed we put everything together using the components they gave us at the beginning of class. We continued to follow the steps of putting the watch together that I found really cool. The main purpose was to use our minds and our hands to make products. I thought it was really cool to work with our entire class to work and I really felt like I was becoming much more open-minded with my thought process. I had never really put together anything like this before and I found a lot of goof lessons in the process of learing how to build something form scratch.

Storyboarding

After we completed the work on our watch, we began the work on storyboard for our own projects. The objective of this exercise was to help groups visualize the process of our products being used. It gave all of our groups the opportunity to understand our products life cycle. It was nice to collaborate between our groups to create a better long term plan in our products life cycle. This was also great to better understand the end goal and our products perception by our users. By understanding our products end goal we can better understand how to make the best decisions in the beginning stages of the product. By talking and reading other groups conversations I think many people found this exercise very beneficial. I linked some helpful photo below that our groups shared to best dive into the storyboards.

Next steps moving forward I think our class needs to start preparing for our upcoming Make-a-thon. We are meeting on Tuesday to further understand the purpose of our projects and hear more about the Make-a-thon. I think that these next few weeks coming off of spring break are going to be really great for our projects. We have spent a lot of time theorizing and understanding our projects scope and now with time expiring on the semester its time for more advanced prototyping. Im excited for my group and to see the amazing ideas of other groups come to life!

Week 9: FabLab Round 3

Watch Assembly

After 2 weeks of prep in the FabLab this was the time when we are able to put all of it together. As a reminder in the first 2 class sessions, we learned how to build and construct a circuit and learned how to laser cut and design in ink scape. When we arrived to class we we introduced to some pieces to help make a circuit board to operate our watch. After a brief introduction we started working with a program to help tell our watch what to do. We did a couple exercises we programed our circuit board to pair with the tilt sensors so our watch an work. After we learned and downloaded out program, we went to work on our assembly. Honestly, I thought it would be worse than it was. After we super glued the circuit board to the bottom part of the watch it all just started to come together. I was incredibly fun after just a quick 3 sessions at the FabLab we were able to conceptualize and make this product.

Storyboarding

For the remainder of the class, we broke off from making the watched into our project teams to storyboard our product. We began with u users and wanted to highlight Jenna. We saw the next step was to raise awareness on our product through word of mouth mostly. Thirdly was to picture the initial purchase of our product which we saw to be done at a department sports store like Dick’s. We then needed correct descriptions of how to use the products best. Next, we depicted the user first putting on the product and transitioning them to a product they use every day. This was a great exercise that helped us lay out the timeline was looking for our product down the road. I think that this helped us gain perspective on our product and begin to lead us in the right direction. 

Round #2 at the FabLab

Introduction to InkScape

After our last week in class having an introduction to the electronics end of our physical therapy watch now we got to work on the watch its self. Firstly, to do this we needed to work on our software skills so we could design the watch. That is when we were introduced to InkScape. InkScape is a program the allows us to model our prints in 2D instead of 3D. This is important because for the laser cutters that we would be using in the FabLab we need to be able to model in 2D for the cutters to understand. After a quick tutorial on the basics of InkScape we were tasked on creating our watch face so the user would be able to know if the watch function was set to measure “twists” or “curls”.

For this, I saw many of my classmate making elaborate text and designs to represent the different functions. I decided when tackling this problem I wanted to make my design as simple as possible. Therefore, I rastered two notched on my watch face so the user could know when its set to twist. The reason I decided to this was that since the product only has two functions I felt the user would gage fairly quickly if it wasn’t in twist mode, it’d be in curl mode.

Introduction to Sewing

One of the coolest things about the FabLab is all the different and creative ways that they can teach us to make the cool amazing products. From the beginning of the semester, I though this course would be respricted to just 3D printing, but what ive noticed is that even 3D printing has its limitations.

After, our introduction to InkScape and creating our watch faces, we moved onto making our straps for the watch. This was really cool because I hadn’t been on a sewing machine since 7th grade so it was awesome relearning this really cool skill. We cut, ironed, sewed, and attached velcro to our staps so we could later attach them to our watches next week.

Meeting with Milestone Labs

We had a very interesting meeting with Milestone Labs. From the week before we felt very prepared as we came to class with 4 separate prototypes to show them. Although they liked our design and I fell like they were impressed with our work the gave us great points of criticism. They first challenged us to go take a deeper look as to what was in the market already. Although we have talked with 2 users of the C-Leg, we really didn’t have too much of an idea of the competitive products in the industry. Secondly, they challegended us to think of what type of material we would be using. Although it feels early in the process the material we choose is a vital part of the success of our project.

After our meeting, we were lucky enough to get the time and speak with Jenna about the comments we heard and to try out our prototypes. After some trials, Jenna gave us some more great advice as to how we could improve our products. We deliberated some more and came to an idea that would be lightweight and be fully protective of the leg and knee area. We had an idea where the guard would latch on the mack of Jenna’s leg and the top of her knee. This design would allow for the product to be protective, lightweight and give Jenna a full range of motion.

Laser Cutting

Later in the day Wednesday, I returned to the FabLab to laser print my watch face. This was really cool and it provided me a really unique experience to use a laser cutter. There were a few specific specifications I had to make to calibrate the laser cutter but with some help I was able to figure it out. It was a really quick and cool experience and I hope we get to use this technology at some point in our project.

Week 7 Reflection

FabLab Part 1

This week our class got introduced to the Fabrication Lab a.k.a. FabLab. We received tons of help from all the great staff that devotes their time there to help us learn. When there we first got a tour of the facility. We saw their computer lab where students can work on all sorts of design programs. Then we moved into their work station bench where they had tons of successful designs they have created. After, we moved into the other room where they showed us a lot of their very cool designing machines. They really gave us another perspective of design outside of just 3D printing.

One awesome thing that my group noticed is how the used a laser cutting machine to create a leg shaped structure out of wood. They then used that structure as their base and melted some type of plastic over it and it took shape of the structured design. I thought this was so cool because this connected really well with our project on how we could create a leg guard for Jenna outside of 3D printing.

Circuit made with Colton

Additionally, at the FabLab, we broke off into two separate groups. My group was led by Colton that shows us how to work a circuit. I have not really worked with circuits since freshman year of high school so I had a lot to relearn. We used a watch battery, a small LED light and resistors to demonstrate how to turn a light bulb on in a current. The whole purpose of this activity was to really show how to blend technology and design together and to get us to think about how we could incorporate this lesson into our products.

Finally, We came back together as a class to brainstorm more about our projects. My group found this really helpful to get our ideas back on the table. The activity was really fun because we had to place ourselves in different situations to see how we could alter our project. For example, one of the situations was, “If you had unlimited money vs. if you had no money at all?”. Was really cool to see the different types of designs we made within these separate constraints.

Class Activity Design Board

Project Update

This week we have had a very productive time advancing our project. Earlier this week we had a meeting with our first secondary user other than Jenna. Jenna set us up with her physical therapist at DRES. Although I was unable to be at the meeting because of class, the meeting went very well and we took a lot of the ideas into our prototypes. One, idea that we got was to place most of our focus on protecting the knee because that is the most important part. Many other products on the market are bulky because they focus alot on protecting scratches.

After our discussion in class Jay, Nathan and I decided to meet to build upon our ideas. We met Saturday to go to the Art and Design building to create some prototypes of our knee protector. Based on our interviews with Jenna and her Physical Therapist, we had some ideas to run with. We created designes with buttons, that were flexible, that had fabric sleeves and that had special latches. We really wanted to grasp a wide array of designes while we were prototyping. Below are the designs we made and all the fun we had creating them!

Week 6 Reflection

Fusion 360 Tutorial

Prior to arriving to class, we took time to learn Fusion 360 by both watching videos on the Autodesk website and also creating our own Box by Lars Christensen’s tutorial on YouTube. I really enjoyed these videos as I believe they gave us a nice understanding of our in-class activity.

In class, we arrived and jumped into our groups to learn more on Fusion 360 from Dan Banach. Dan was a great speaker and really helped up learn how to functionally operate the tool better. Dan began by explaining that the hardest thing to do in any designing phase is trying to break it down into simpler shapes. To do this Dan walked us through the process of making a custom phone stand. Dan really helped us understand the entices of the tool much better. I was able to make this phone holder:

Weekly Project Update

As our search for secondary users for our product continues we continued to analyze our problem statement and questions. In the second half of class, we structured our project in a more cleaner format that helped organize our thoughts.

On Friday, we were able to meet up with Jenna to get a scan of her leg. This was essential for us to get so we could create accurate measurements of our product. We’re very thankful for Jenna being so helpful for this entire process of our project.

Moving forward, we need to meet as a group to hash out design ideas for our protective knee pad for Jenna. I think with the scan and the 2 hours next week developing our Fusion 360 skills we should have a product drafted by the next couple weeks. Very excited to see where the next couple weeks take us.

Jenna’s Leg Scan
Jay holding Jenna’s Leg for the scan