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

Kate Garvey E-Portfolio

Coming into this course, I didn’t really know what to expect. I heard about it in Dr. McDonagh’s Disability + Relevant design course. Since I really enjoyed that class, I thought I might enjoy this one as well. I had heard about Arielle’s company Ingenium in that course, and was very impressed to hear that the product she sells was first created in Digital Making. That really sparked my interest in the class even further.

When the semester began, I expected the class to focus a lot on 3D printing. I was surprised to find out that it was going to be set up more like the kind of studio class I am familiar with. This got me excited because I was eager to experience a design course from a more outside realm. We spent a lot of time in class doing brainstorms, research, and iterations, much like my design courses. But what was new for me about this course was having an opportunity to work with business students. It was fun to teach them what I know about design and introduce them to the importance and relevance of design thinking.

After having the chance to visit DRES early in the semester really sparked my interest in working with the wheelchair track team. We also had the chance to meet the mentors and meet Arielle. It was cool to hear her talk about her story and have the chance to see someone, and not necessarily even a designer, create a product and then profit from its creation is just so exciting for me to see. She really found an area that needed improvement, no matter the scale, and took off with it. This really got me as well as my team excited about working with her.

After deciding we wanted to work with Arielle, we got the chance to meet up with her and discuss the opportunities further. She told us about the struggles the team faces with their hand rings. She told us how during poor weather conditions, racing becomes even more difficult as you no longer have a good grip on the hand rings of the chair. We were lucky to be invited to visit the team practice and get a chance to have a closer look at the chairs, the hand rings, the gloves, and the process that goes into preparing your chair for a race. Wrapping the hand ring is such a difficult and time consuming task, we knew it would be so great to find a way to streamline that process into something more efficient and easier to do.

During the following weeks, we begun to really think about how we might find a good solution for our opportunity. We begun to discuss what materials we might want to test with our prototype. We decided to test how adding snaps to the existing hand ring, as well as to our materials will hold up. We also wanted to test various materials around the ring to hopefully find one that creates the best friction.

For the Makeathon, we purchased a variety of materials including a bath mat and a yoga mat. During the Makeathon, we quickly realized that our materials were very soft and didn’t withstand even minimal testing with the glove. We found that our most promising solution was to pursue to Plasti Dip. We discovered that there was a spray version available, which seemed to be a good and easy option. After the Makeathon, we purchased a can of the spray Plasti Dip to create another prototype. We used the spray booth in Art + Design to coat the hand rings and the gloves. The spray was so easy to use. We did the recommended three coats, waiting 30 minutes between each and four hours for it to dry. After it had dried, it had created a nice even coat that was slightly sticky to the touch.

We met with Joey Gibbs from the racing team to test the prototype. Once we arrived at the DRES morning practice, Joey was able to remove one of the hand rings from his chair and attach our prototype to it. The glove we had sprayed was not Joey’s size, so he wants able to test the glove with the ring. However, we did see Jenna, another racer and mentor from our class, and she was able to test the glove for us. After going about 40 feet, the Plasti Dip on the glove started peeling away immediately. We quickly realized this was not a solution.

Once Joey was ready to start practicing using our prototype, he quickly realized that the Plasti Dip created the perfect amount of friction between his glove and the ring. It was sticky enough to create a good grip, but not too sticky that it slowed down his stroke. After about five minutes of Joey practicing at a regular speed, we could see that the rubber spray coating was starting to peel away. Even though it was peeling away, it didn’t affect Joey’s speed or efficiency. After about 15 minutes, the rubber on the ring was almost worn away. We noticed that one section of the ring, however, was withstanding Joey’s strokes. Once we took a closer look at the ring, we realized the part that was no peeling was the part that we had coated with Plasti Dip at the Makeathon. This lead us to believe that our potential solution might be stronger if both types of Plasti Dip are used or if more coats are applied. In the end, Joey had found that his overall speed was actually 1 mph faster with our prototype than normal. This was an exciting finding! We think that if the team pursues trying this material in various ways, they might find a solution that is easier and more effective.

This class was a great learning experience. Though it was different than what I had expected in terms of what we actually did during the class, I still enjoyed it. The best part for me was having the chance to work with business students and learn more about their point of view when it comes to problem solving and design. I learned that I have better problem solving skills than I thought, which was an exciting self discovery.

https://digitalmaking.web.illinois.edu/spring2019/team-four-project-reflection/?preview_id=2389&preview_nonce=ce857f17ee&preview=true

When the Course comes to an end

Course Expectations

My journey in this course all started when I was looking for additional interesting courses to take before the course registration day. After I selected all the courses that allow me to fulfill my graduation requirement, I noticed that I still have the credit hours available to select two courses of my own interest, so I started looking for additional interesting courses on the course explorer. When the course name “Digital Making Seminar” came in front of my eye, I was so amazed that the business school would offer such a course that is related heavily with 3D printing and other types of digital making as well as product design, so I applied. Before the start of the course, I expected the course to have more focus on technical skills, including 3D printing, 3D modeling, 3D scanning, and other digital making skills. But when I entered the course, I noticed that this year we have a focus on the accessible design. This was definitely something that I did not expect, but this did not mean that I didn’t like this course.

Course Experience

During the course, I learned a lot of technical skills that I previously expected, but these skills are not all touched on a deeper level than I expected. This makes me think that my initial expectations of this course was not fully met. However, I learned more things that I did not expect previously, which filled the gap of the unmet expectations. This semester, the course focused primarily on human-centered design with a focus on accessibility design. I think, the primary goal of this course was very inspiring and the overall experience was great without focusing on what my expectations were prior to the course.

In week 2, we visited the Disability Resources & Educational Services facility. This was the first time we met the mentors, people who used their stories to give us inspirations on accessibility product designs. In this experience, I learned how to interview others, learn from their stories while keeping empathy in mind. From these stories and experiences that the mentors told us, I learned to seize the opportunities within these stories and experiences. I also found it very important to understand that people with disabilities are nothing different from people without disabilities. When we are designing items that could improve the user experience that people with disabilities have, we could also apply the same or similar ideas to improve the user experience of people without disabilities. It is more important to capture the opportunities. From this experience, I also learned that I was capturing the opportunities slower than others, perhaps, this was why I was not a designer in the first place. But I learned that even if this was true, I could still come up with design ideas that could improve user experience.

In week 3, we met the Milestone Labs online due to the extreme weather in Champaign on the day of the class. We learned about how the experts from Milestone Labs approach to design problems, discovery opportunities and brainstorm solutions for an opportunity. This was also the first time I realized that people, including me, are so creative in finding simple solutions to overcome small challenges that exist in our everyday lives. However, we usually did not realize that we are solving the small challenges within our daily lives with such simple solutions. I was shocked that I have been so creative in solving the daily challenges that came up as well. I think a big takeaway from this was that we should not overcomplicate problems when there could be a simple solution, and we should not ignore our creativity. From this experience, I became more confident in myself on my ability to solve problems to improve our user experience.

In week 4, we learned about that failure was nothing to afraid of from the presentation conducted by Mike from EarthSense. Instead, we need to learn from failures and fail early to improve our design from the things we learned from our failures. This was very helpful in our later product design stages. In addition to this, we also how to 3D model on tinkercad. We designed our team logo, turned it into a design model on tinkercad, and 3D printed the model. This was our first of a few experiences of 3D modeling and printing in this course.

In week 5, we learned about the needs of another potential mentor group, Illini Service Dogs. We also learned about the development of 3D printing and its applications in the health industry. We were amazed and inspired by how 3D printing made many unsolved challenges in the health industry possible to solve and how people were inspired by 3D printing to improve the experience in the health industry. We also learned about the fab lab and the tools that are available in the fab lab. I think this week gave me an introduction to the resources available on campus that I did not previously know about. I think this was one of the most useful takeaway coming out from this course – I learned that I could utilize the resources available on campus to do things that fit my interests.

In week 6, we finally had an advanced learning on 3D modeling using FUSION 360, which was another few experiences in class that we actually learned the technical skills.

In week 7-9, we learned the tools available in the fab lab and took our brainstorming of design and prototyping forward. In the fab lab, we learned how to design for laser cutting on Inkscape, how to play with the electronics on the breadboard, and how to input codes on Arduino to make this microcomputer to perform the tasks that we wanted it to perform. Besides the skills that we learned in the fab lab, we also brainstormed ideas about the design of our prototype, made our first low-fidelity prototype, collected user feedback, learned from experts’ recommendations and interviews, adjusted the design of our prototype, and designed our storyboard, which served as a plan of how our users would use the product and how we would market our prototype. We also conducted market research on similar products and how our product would be different and unique so that it could capture the opportunities that exist in the market.

In week 10-11, we spent time in preparing for the Make-a-thon. We met new mentors, spent our time listening to their stories and needs. To be honest, I thought that the time we spent in week 10 was actually a waste of time since the major focus was to introduce mentors to students from another course who are also participating in the Make-a-thon. Although the new mentors had great stories that we could learn new opportunities from the new mentors, we were not able to change our approach since our design focus was on improving Jenna and other amputees’ yoga experience, and she actually hoped to get a functional product out from us to improve her experience in yoga. In week 11, we spent time in meeting with the experts from Milestone Labs, learned about the limitations that our team has and how to improve our design for the product. In this week’s experience, I actually learned about the limitations that I had. I am not a design student, and I was lack of the art skills that I could not make sketches and express my ideas clearly enough, even though I had a picture in mind of what the design would look like. Therefore, we consulted with FUSION 360 experts in making sketches of our prototype and making the 3D model of our prototype.

During this period of time, I also completed my once per semester project on 3D printing’s impact on the food industry. This was something that I was particularly interested in. This was also something that allowed me to learn a lot about the 3D printing technology and the benefits and disadvantages it could bring to our daily lives.

In week 12, prior to the Make-a-thon, we finalized our first 3D model of our prototype and 3D printed a scale version of our prototype. We met our new member who would join us during the Make-a-thon.

In the weekends of week 12, the Make-a-thon started. The Make-a-thon experienced was not bad, but it was not the best too. Entering the Make-a-thon without my two teammates but with a new teammate was a challenge. Not to say that we were not in the same page about our product design due to the fact that our new teammate did not have enough knowledge about our design, we encountered many problems of our original design that we would need to deal with. Both of us did not have enough knowledge of FUSION 360, and we also did not have our mentor. We faced a lot of challenges that would cause us in our progress that we would not able to move forward. Although this experience sounds negative til this point, the experience was actually very positive. I learned to deal with my teammate when we had different ideas. We learned how to compromise, but we also learned to move on first when we got stuck into one challenge that would waste our limited time. We learned how to consult with experts and utilize the experts who are available to us during the Make-a-thon. I would always remember how proud I was when three experts and my teammate were debating over the physics of our design and the problems that we might encounter with the 3D model of our second design. Although debates might not seem positive, this was a sign of failing early so that we were about to fix the failures to improve our design. I would rather experience this in the early stages so that we did not make the failing products due to our lack of knowledge in physics and material science. This was an important lesson that I learned from the Make-a-thon: fail early and make improvements to the design utilizing the feedback and actively consult with the experts so that our design would not be failing due to our lack of knowledge.

The challenge came up also due to the fact that we did not have our mentor, Jenna, during the Make-a-thon to test out our product. This made us went for another approach during the Make-a-thon, which to design a product that could be used not just for prosthetic users so that we could actually test out the functionality without Jenna. After the Make-a-thon, we tested the product with Jenna. The test showed success in concept, but a failure in the actual functionality due to the fact that Jenna’s prosthetic leg was different from the actual human leg, which has muscles that could provide us additional support. The prototype we made during the Make-a-thon could improve the lateral balance but only limited to the portion below her ankle. This made us went back to the original design of a prosthetic replacement for yoga.

In the end, we finally came up with a functional prototype after multiple prototype testing with Jenna followed by multiple iterations to the design. I would say that this course helped me grow in problem-solving skills. I also went through a full stage of human-centered design and product development. With a functional prototype coming out of the course, I am very proud of the work we have done during the short semester in the course. If I could choose the course again, I would definitely do so even if it did not fully meet my original expectations.

Did we Evinco? e-portfoilo​ by Maryam

To explain the title, Evinco is the latin word for prevail or overcome. (“Did we prevail?”) However, it is also the word that my team chose to represent our project this semester. We worked with Arielle Rausin as our mentor and tried to overcome challenges in Paralympic wheelchair racing.

At the beginning of this course, I expected to focus a lot more on 3D printing. My group was very worried because we weren’t sure how we would 3D print something that related to our project idea and goals. Our goal was to improve an athlete’s grip during undesirable weather conditions. However, besides the practice with Fusion 360 we did very little 3D printing in this class. The experience was also different because we were assigned mentors. I think personally, I expected to be able to design a product myself or with a team. However, after we were presented mentors it really focused our efforts. I think this was a good thing because we were able to make an impact. However, it also was very hard in the beginning because we really had to understand the experience of the mentors and work on an empathetic design approach.

I think I learned a lot about myself this semester. When I entered the class I greatly doubted my design capabilities. However, I quickly realized that I actually have valuable design experience from my T&M classes! I already knew what a design brainstorm was and was able to use my imagination to think outside the box. Also, I was able to learn more about empathetic design. I know Professor Deanna was talking about a class she leads in empathetic design and how she has her students put on blindfolds and use walking canes for a day. I thought this was really interesting and I wish I could have taken a class about empathetic design in college.

I don’t know where to begin when recapping everything I learned over the semester! My first post was about our class visit to DRES. This was when I first met my mentor for the semester Arielle and learned about her previous experience in the same class. I also learned about her company, Ingenium which was the basis and the inspiration for our class! https://digitalmaking.web.illinois.edu/spring2019/week-2-reflection-2/

Week 3 was when we first started learning about design thinking and had an introduction from milestone labs. One of my big takeaways was a design can almost always be improved. Milestone did a great job of pointing out how people come up with design hacks daily and just because these hacks work, it doesn’t mean they are necessarily the best version. https://digitalmaking.web.illinois.edu/spring2019/week-3-reflection/

During Week 4 I learned a lot for my project. We create our team name, logo and used Arielle’s company Ingenium as our inspiration. However, we also went to DRES to visit the team during one of their practices. Here are some of my notes that were key learnings for my team. “The first thing that was helpful to learn was that the hand ring is re-gripped about every 3 months. The ring is unscrewed from the wheel and a tire tubing is placed around the ring. Contact cement is used to attach the tubing and it is heat activated for a heat gun has to be used to pull the tubing off. It is about a 4-hour process to change the grip and it has to dry for a day. Elisa asked if there was a company that changed the grips and we were all shocked to find that there was none. All the athletes have to learn to change the grip themselves and some of them will even pay their other team members to do it for them.” https://digitalmaking.web.illinois.edu/spring2019/week-4-evinco/

Week 5 was our first project brainstorming session. I remember Adam attended our class that day and our team got a little off topic because Adam was so excited about our project! He had all these amazing ideas and we are so appreciative that he shared them with our team! https://digitalmaking.web.illinois.edu/spring2019/evinco-week-5-applications-of-3d-printing/(opens in a new tab)

Week 6 is when we started learning about 3D printing and got the opportunity to try our Fusion 360. This was one of my favorite weeks because this related to my overall expectations for the class and my desire to learn technical skills. https://digitalmaking.web.illinois.edu/spring2019/week-6-team-envinco-fusion/

Week 7, 8 and 9 were spent at the Fab Lab. We spent time getting trained on the different tools and had the opportunity to build a watch that was meant for users who need physical therapy on their hands or wrist. You can see the steps we took in the three posts below. https://digitalmaking.web.illinois.edu/spring2019/a-lab-that-is-truly-fabulous/

https://digitalmaking.web.illinois.edu/spring2019/week-8-sewing-pros/(opens in a new tab)

https://digitalmaking.web.illinois.edu/spring2019/week-9-watch-what-we-can-do/(opens in a new tab)

Week 10 for me was the least productive. I had to miss our class session for my Supply Chain class. However, our team did do some research on what was currently in the market. This ended up not being super successful because there were no products related to wheelchair racing in the market and we looked at normal wheelchairs. https://digitalmaking.web.illinois.edu/spring2019/week-10-making-moves/(opens in a new tab)

Week 11 was preparations leading up to the makeathon and week 12 was the makeathon. These are the weeks where I learned the most in this class. Leading up to the makeathon we researched materials and met with a material science professor. We gained super valuable information for our project and I wish we had more time to do actual reserach and preparations because then our team would have been able to order a more specific material. https://digitalmaking.web.illinois.edu/spring2019/week-11-pre-make-a-thon/

https://digitalmaking.web.illinois.edu/spring2019/make-a-thon-success/(opens in a new tab) 

Semester full of Digital Making !

Wow the semester has flew by. I remember taking my disability design course and being heavily encouraged to take this course from my professor Dr Deana McDonagh. I heard countless success stories and instantly got interested. I remember the entire process  of sending a resume and asking access from the instructor. It made the course feel even more official and selective. I wanted to take the course because it could present even more fabrication resources and help me in product development in my startup.

Expectations…

Initially I didn’t necessarily know what to expect. From the course description I thought maybe the the class would be very hands on and explore various methods of fabrication. Even with these little to no expectations the course don’t over promise anything. The course itself wasn’t perfect but it was an overall great experience. It challenged us to think outside the box and look at what we usually consider problems as areas of opportunity for innovation. The structure of the course prompted us to use the parameters set and essentially work through things, which allowed us to learn even more. This style of teaching could go one of two ways. The class could be way to lose, which causes confusion and lack of understanding of expectations. Or it could be how this course went and really give students the opportunity to explore, fail, plan, and execute on an idea.

This course further enhanced some fabrication skills I already have and taught me some fairly new ones as well. As an industrial designer I’m constantly doing project and solving problems. Design thinking, user centered design, empathic design are all things this course subtly hinted in throughout the semester. The workshops enabled us to gain new skills and learn processes. Many of, if not all the guest speakers, provided meaningful insight throughout the semester as well. There are so many takeaways from this class.

Solestice

I was partnered with two bright young women from the college of business. I couldn’t have asked for a better team. We had a great dynamic and right away knew what we wanted to do for the remainder of the semester project.Through the many conducted interviews and mentors stories we gravitated towards Jenna. She shared with us the story of a time where she slipped on ice immediately after exiting her car. This happened all because she can’t wear boots due to the heavy nature of them. This prevents users like Jenna  and other prosthetic users from wearing them as their residual limbs are not strong enough to carry the amount of weight the boot has. This is where Solstice was birthed. We aimed to figure out a way for Jenna to increase traction without adding adding additional weight to her shoes. Our main goal was To create an attachable, lightweight shoe tread that can be used to travel in a variety of terrains.

Low Fidelity Prototype

My group and I brainstormed countless times trying to figure out how to make this idea into a real thing. We’d sketch  ideas and somehow came up with the thought of incorporating spikes ( like in track shoes) it would help with traction. Unfortunately after creating a low fidelity we realized that our user may be required to take said device off when walking indoors. We also wanted to make it as easy to use as possible, while providing a comfortable fit we thought to use velcro. This set us up perfectly to further ideate on this idea and create our very own functioning prototype at the makeathon.

At the Make-a-thon itself team Solstice focused on three main components of creating this product:  Arduino, molding, and attaching. The arduino portion was super cool and challenging. It was my first time coding and working with circuitry. Essentially this would add a unique tech factor to our tread that would allow users to have a sense of force feedback. From research we found prosthetic users have issues shifting weight which can lead to gaits abnormalities. This small pressure sensor would give them that data and in term help prevent this from happening. The design itself was fairly simple. We coded an Arduino Uno to illuminate LED lights that indicated pressure being applied. To create the pressure sensor, we sandwiched a piece of foam with two pieces of copper. Ideally, we wanted for there to be three lights, each indicating where the user is putting pressure on the tread. This would enable the user to ensure they are putting enough weight on their prosthetic to maximize stability.

In terms of creating the tread it we wanted to use a molding compound. This would allow for a lightweight thread, but ensure a grip tread form that resembles that of your regular high traction shoe. We created a mold of a shoe outsole. During this process, we coated the shoe in baby powder and mixed the molding compound to a viscosity similar to pancake mix. We held the shoe down until the mold dried. Following, we used a hot glue gun to fill in the mold with thermoplastic material. After the mold was completely filled, we used a heat gun to smooth the top of the sole, making sure the edges were slightly taller than the inside of the sole. The thermoplastic material we used was similar to silicone and, per our research, is a material that creates enough friction to prevent falling on ice.

For the sake of time and resources we opted to utilize velcro for our attaching method. It wasn’t the worst choice but also wasn’t the best as it came with its own constraints.

Overall I really did enjoy this course. From the challenging nature of it to its looseness it was a great experience. I got to learn new and exciting skills. I got to meet some amazing people. Most of all I got to make something with newly found campus wide resources. I’ve really grown as a individual because of this course. I find myself a better teammate. The collaborative portion of this course really ties teams together and promotes all hands. Hopefully you’ll see a team Solstice sole on the market. We really did nurture this product and can’t wait to see it reach its full potential. Never stop making!


Team 3: Project Reflection

Introduction:

Welcome to Vizallo! Throughout the semester, we built silicone cover solutions to prevent water from damaging electronics in power wheelchairs. We are a team of 4, comprised of 2 technical business students, a computer science major and a very talented industrial designer.

Ryan’s Story:

Our journey began when we were introduced to Ryan, a recent UIUC graduate and a power wheelchair user himself. We heard unbelievable stories of his multi-thousand-dollar machine simply powering off in the rain because of circuit leakage – and we could not believe it. Ryan resorted to literally using a Ziploc bag to protect the electronics to avoid being stuck helplessly in the rain, banking on kind pedestrians to assist him in getting under a roof. It didn’t take us long to commit to embarking on this semester-long design challenge and trying to help Ryan find a sustainable way to stay dry in the rain.  

Research:

We first decided to look into the market to identify the different options that are available for the purpose of protecting the electronics on the power wheelchair. Although there are several brands with the offerings, most of the options available apply the same concept. They look like a little quarantine tent, where the user would insert his or her hand into to operate the joystick of the power wheelchair.

We realized that these types of covers have many flaws and thus, a big space for us to make improvements on. For example, there are many complaints about the product not being able to hold against heavy rain. It could successfully prevent light drizzles from entering through but under heavy rain, the water could still enter through, thus failing to provide its primary purpose of protecting the electronics of the power wheelchair from the weather. Additionally, because the products are so big and bulky, the users always take them off when it is not raining outside. This means that the users often forget to bring the products with them or get caught in the rain by surprise without having access to them. Furthermore, the designs of the products are not appealing to the users, discouraging them from continuous use.

Design Process:

The design process was not easy. To create what seemed to be a simple solution, such as using an umbrella, was not beneficial for our user. This is when we really became challenged by the design prompt. We came up with extreme ideas from protectant fields to very simple ideas such as utilizing saran wrap. After talking with Ryan about his desire to ride in a Ferrari, our perspective changed and we realized that in order to design something effective, we had to thoroughly consider the user. Coming to this awareness really enabled us to focus on the actual problem, which is to protect the joystick. Although we thought of coming up with solutions that will protect the entire chair from the rain or even his hand, in order to design effectively, we had to consider how every aspect of our design was going to affect Ryan.

After gaining an understanding of what is available on the market, we decided to poke around other protective covers to gain inspiration for our product. We did not limit ourselves to the power wheelchair related products and looked far beyond. For example, we looked into baby strollers and convertible cars to gain inspiration for the “armadillo-style” protective cover. We even looked at phone cases to come up with an idea of a “perfect-fit skin” for the arm of the power wheelchair.

Our goal was simple: create a product that is easy and effective. Since we could not exactly predict the other weather conditions that may come with rainfall such as wind, we had to simplify some of our ideas. This is when the phone case idea provided major inspiration. The phone case is an everyday product that is not only practical but also customizable. Those are two characteristics that we did not notice in other power wheelchair protective covers available on the market. So from there, our goal was to create a product that serves as a skin cover for the joystick, thus allowing it to be mobile, simple, and provide a room to add customization.

Make-A-Thon:

Leading up to the Make-A-Thon, we spent most of our time brainstorming. Going into the Make-A-Thon, we had a solid idea of what we wanted to produce but we weren’t quite sure of the process. Our first step involved creating a mold of the joystick. Since we did not get to scanning and 3D-printing the actual joystick until weeks later, we created a model of a joystick out of styrofoam. After this stage, we were again, unsure of our next steps, and so we tried to develop a prototype that incorporated everyone’s ideas.

We decided to develop on the sleeve cover idea, for which, we tried out the heat gun. The goal was to use heat in some way to get the plastic to shrink to the form of the joystick prototype. Unfortunately, this was not very successful. Some of the plastic and styrofoam melted and the rest refused to stick to the prototype. However, what we did discover was that the plastic, when heated would stick to itself. Therefore, after we came up with another idea, which was to cut the fabric into pieces and piece the pieces together with hot glue, we utilized the heat gun to seal the seams.

While looking for inspiration, we also ran into covers/skins with texture such as the one on game controllers. This inspired us to make grips out of moldable plastic that we then added to our prototype for additional support when the joystick gets slippery. The overall process worked out great and after we added a couple of details, we were done with the prototype for the Make-A-Thon.

Post-Make-A-Thon:

After the Make-A-Thon, we continued to work on the next version of the prototype, which would be closer to what we would hope to put on the market. In order to make the prototype more accurate, we scanned the joystick of Ryan’s power wheelchair, with which we 3D printed the mold. Unfortunately, due to the size of the arm of the power wheelchair, we had to scale the mold down and only focus on the part with the joystick to serve as a demonstration. With the scan of the arm of the power wheelchair, we used Meshmixer to isolate the part with the joystick. We also used the software to fill any gaps from the scan.

The file was then transferred to Fusion 360, where the mold is designed based on the scan. Our idea is that we have a base of the mold with the scanned joystick, which will be enclosed by the top that has a slightly larger negative image of the joystick. Therefore, when the top encloses the base, there will be a slight gap between the base and the top, through which silicon will be inserted to produce the sleeve cover. We were unable to try the silicon injection but we were able to successfully print out the top and the base of the mold.

Next Steps/Testing:

Although the semester wrapped up and the project ended, we decided to share what we have planned on doing further if we were to have more time. For example, we planned on performing more user testing. This will allow us to gain perspectives from the other power wheelchair users and also test the scalability of the product by having them give us feedback. This will also give us valuable insight into the user interface/user experience process of putting on and removing the silicone cover. Since certain users may have less dexterity function than Ryan, we must ensure that we can accommodate everyone.

Next, once we have validated with a broader range of users, we would look into manufacturing the silicone cover at a slightly larger scale. However, we will probably only leverage the database we would have built up from working one on one with the other power wheelchair users. Nonetheless, since there is such a limited amount of power wheelchair manufacturers, this would help us cover a substantial part of the market.

Ultimately, we would look to encompass the rest of the market through more one-on-one testing and database logging or try to leverage the OEMs and use their molds directly from the production line. This is where the large scale manufacturing and distribution comes into play, otherwise known as our moonshot.

This is an enormous industry as a whole. According to Smart Chair, the power wheelchair market alone was valued at $3.9 billion. This is a large market which can be easily infiltrated due to the staggeringly low amount of wheelchair manufacturers that exist. According to IBIS World, there are only 21 wheelchair manufacturers in the US, and it is likely that not all of them make power wheelchairs.

Hence why we justified growing a digital database one-by-one based on individual user testing. Since there is a maximum of 21 different models which we would need to model and manufacture for, hustling and meeting users of each type is not completely out of the question. The manufacturer concentration in this market actually plays heavily to our long-term advantage.

The final presentation for my team can be found here: Team 3 Final Presentation.

Goodbye – Final Reflection

As the semester comes to the close this is a summary of what I’ve gained and learned from the Digital Making Class. For me, it was a different experience taking a class that is project based. However, it was nice to have a change of environment and pace for a change. In the next couple of paragraphs, I will highlight what I expected from the class and what I actually got out of it.

I was introduced to this class through an instructor. In high school, I volunteered at the Museum of Science and Industry in their Fabrication Laboratory. I love to learn through experimenting, so I thought the class was a great opportunity to get back into fabrication. I did not know anyone who took the class at the time, so I skimmed through a couple of the blog posts and saw interesting topics such as Arduino learning and 3d printing. Therefore, going into the course I expected it to be a hands-on, interactive space to explore various topic connected with fabrication. Looking back some of my expectations were met but not necessarily all. Most of the class time was spent learning about other people’s stories and completing brainstorming exercises. However, I came to realize that it was good that we were doing a lot of reflection. I remember a quote from the beginning of the semester that stressed the importance of analyzing the problem instead of being quick to come up with a solution. Although the class was not quite as I expected, I still felt challenged by the prompt which was to design assistive tech.

What I learned:

Technical Skills:

Throughout the semester we completed a couple of hands-on workshops in the Fab Lab. One of those workshops involved building a watch for physical therapy patients from scratch. As a result of this workshop, we learned how to use and code an Arduino, sew, laser cut, and use a software program called Inkscape. This workshop took us about three class days to complete. Before coming to college, I learned how to use a laser cutter and Inkscape. I’ve also worked with a Raspberry Pi before which is similar to an Arduino and had previous experience with sewing. The individual workshops were helpful I talked about all of them in some of my blog posts here.

Earlier in the semester we also had another technical workshop hosted by Autodesk. A representative from Autodesk taught us the basics of Fusion 360. In the workshop we designed a phone case stand, I talked about the experience in this blog post here. To my surprise Fusion 360 is fairly easy to use. Although for my team’s project we did not utilize fusion, I still found the tutorial to be beneficial.

In general, the technical workshops were my favorite part of the course. I am a hands-on learner, so it was exciting to actually fabricate. However, I wished the course was comprised of a variety of workshops that happened more than a couple of class days.

Creative Skills:

The course also encouraged the building of what I like to call creative skills. This happened when we spent class time in our groups brainstorming. Since we had a fixed prompt it was essential that we all collaborated. Being in a team with business and design students made that collaboration easier. Throughout the semester we had brainstorming exercises such as writing important ideas on post-its and designing prototypes. The most memorable was coming up with designs. Knowing what we wanted to create we essentially had to figure out what design would accomplish our goal. We came up with nearly impossible designs and designs that we could implement in a couple of hours. I talk more about this exercise and others in these blog posts here. The area in which creative skills were essential was the interview we had to conduct with our mentor. Going into the interview we did not exactly know what it was that we wanted to create. The interview questions that we asked had to be constructed with a lot of curiosity and creativity. With simple questions such as, “what is your dream car” we were able to gain a more personal perspective of our mentor Ryan. These creative skills that we gained were not only very helpful but also applicable to everyday life.

In conclusion, this course was not exactly what I expected it to be. However, I am glad that I went outside of my comfort zone to learn in a different way.

Samantha McClary Portfolio

Course Experience

Overall, I did not know what to expect from this course. Speaking to students who had taken it before, it did not have the same accessibility design focus as it did this semester. I was excited to learn how to design and 3D print, and I didn’t know what else the semester would bring! While I thought some of the coursework and assignments distracted from our main opportunity and goal to create a product that Jenna could use during yoga to increase balance, overall I learned a lot. I was very happy at the end when presented Jenna with a prototype that she was genuinely very excited about. I hope if nothing else that Jenna uses our prototype when she does yoga to get better at her practice!

What I Learned

This course brought a lot of different topics together and I learned a lot of both technical and soft skills throughout the weeks.

In Week 2, I was introduced to the mentors for the first time. I learned how to interview, how to prompt others to tell their stories, and how to listen to hear the opportunities in various situations. We also discussed designing with empathy in mind, which comes very naturally when you are able to listen closely and truly hear the opportunities!

In Week 3, things were a bit unorthodox when Champaign was hit with incredibly low temperatures. However, we were still able to hear from Milestone Studio Labs about how they approach designing. I think one big takeaway from this presentation was that sometimes the simplest designs still make a huge impact. This definitely came into play during our design process, as we started overcomplicating rather than creating a helpful solution.

In Week 4, we learned the basics of Fusion 360 design and how to print on the 3D printers. This was the first time I had ever printed anything and it was a very cool technical skill to learn. I think additive creation methods are really awesome to bring your ideas to life quickly. Later in Week 6 we had a more advanced presentation on Fusion 360 from an AutoDesk representative. This was great as we thought 3D printing would be best to allow others outside this class to recreate our design for themselves.

Backtracking a little, in Week 5 we honed our project focus and chose the opportunity wanted to address. Using the sticky note activity we were able to lay out exactly why this opportunity to help with yoga spoke to us and how we could help. When we met with her to discuss working on this opportunity, she was really excited about our choice which confirmed our direction.

Weeks 7, 8, and 9 were spent in the FabLab learning about the tools available to us while creating a motion-sensing watch. This was a great experience because we were able to make a fun product while learning a variety of different tools. We learned how to use the lasers to raster and vector our watch faces. We learned how to use basic programming to program an arduino with tilt sensors. Lastly, we learned how to sew and how all of these different techniques can be used to create a plethora of different products and prototypes.

During these 3 weeks, we also continued work on our opportunity with Jenna. We were able to interview a yoga instructor and the founder of Yoga for Amputees, attend a yoga class, and create low-fidelity prototypes to have critiqued by Milestone Labs.

Weeks 10 and 11 were spend preparing for the Make-a-thon. We met the other two classes who would be participating in the Make-a-thon with us alongside their faculty sponsors. We also continued sketching and ideating using feedback from Jenna along the way to make sure we were creating an effective design. We received help from Fusion experts in starting our 3D CAD file. I learned how to design files so that dimensions can be editable later which was very helpful for our final Instructable.

Finally, the Make-a-thon took place. Unfortunately I was not able to participate but I definitely learned through the experience of my teammates and our preparation. During a Make-a-thon, time is essential. Since 3D printing takes so long, the team used a different approach that would be applicable to more users. Although our final design did not use this approach, it was good to explore multiple avenues and they came out with an awesome prototype shown in Week 13.

Lastly, we created our final prototype! I could not be more proud of everything I learned in Fusion360 that helped me create this design and have the know-how to explain it to others as well. Jenna was really happy with our final prototype and I hope she is able to take it to a yoga class soon to really put it to the test!

E-Porfolio: Course Reflection

Early Expectations

I remember when I first saw the introduction e-mail on this course, I was very intrigued as it was very different from the typical accounting classes I would take. Most of the classes I took do not require me to use my creativity so I thought that this class would be a great opportunity to test it as well as learning about design thinking and other additional skills. So, I went into class looking to be inspired to create and learning to use software to design products to be 3D printed.

Now, after completing the course. I can say that most of my expectations are met. The instructor, Vishal Sachdev, along with the TAs, Charlotte and Mehmet, provided me with an unforgettable learning experience. I am glad that they designed the class to be user-centric so that we are actually designing for someone rather than having us graded base on pre-determined assignments. From the course, I learned how to use tools and resources that I had no previous knowledge of. I also learned to work with people with different skillsets to create a product through design thinking process.

Resources and People

One of my favorited aspect of the course is the people. I not only enjoyed working with my fellow teammates, Samantha McClary and Yingyi Wu, but also the mentors, instructors, and TAs in the course. It was great to be able to create a network among us that goes beyond the scope of the University as we were able to invite many outside speakers and experts to the course. Through my experience working with them, I was able to learn new skills and gain experiences. For example, I had never been to the dress facility prior to taking this course. The course allowed me to not only to visit the facility but work with the individuals there. I have also never been to the FabLab and it was great opportunity to be introduced to the facility as well as the resources. Everyone in the course had a unique set of skills and working style and by having the opportunity to work with them was a pleasure and a great learning experience.

3D Printing Skills

To be able to learn and use 3D printing technology was the primary reason that I chose to sign up for this course. Now, after completing the class, I have to say that I was definitely not disappointed as I was not only able to get my hands-on 3D printers but actually learn how to model 3D prints with software such as Fusion360. It was an awesome to be able to see your ideas get printed as turn into physical products.

Learning to Make

I think for me this was probably the most challenging aspects of the course as I was never asked to “make” something in my previous classes in college. However, I did enjoy the process as it did challenge me to step out of my comfort zone and to develop new skills. I enjoyed how this class encouraged and allowed us to “fail” as it allowed us to refine our ideas/solution and continued to improve our skills. There was no one correct answer as we had to come up with our own solutions and that could even fail at times. It was definitely the most fun but challenging part of the course and I really value the experience of it. I believe that I will be able to use this skill in my professional career in the future as there will be situations were there are no definite solutions and I will have to “make” one.

Key Takeaways from the Digital Making Seminar

After one full semester in BADM 357, I have more takeaways then I previously expected. It is one of the most memorable courses in my academic career and not only we did not have the usual examination to grade our learning process, but we were also provided food regularly as we deplete our energy and brain power for design thinking. My first takeaway is that we should not be afraid of failing as each fail brings up closer to success and give us an edge over everyone else. Secondly, I learned that people are the most valuable resource as each person has their own strength and weaknesses and together, we can accomplish objectives that are impossible to an individual. Lastly, I learned that it is important to keep up technology as it is an essential tool in the business world today.

Team 3D BAL: Finding Balance for Yoga

For our project this semester, we created products that would assist users that have difficulty balancing when performing various activities. We identified this particular need in the market after a discussion with our mentor, Jenna Fesemyer. During our first visit to DRES, Jenna spoke about a variety of difficulties facing prosthetic users. When she spoke about her enthusiasm for practicing yoga and the difficulties she has balancing in certain poses, we agreed this was something we wanted to pursue. We decided that it would be interesting to find a solution to this challenge because it is a rare and unique opportunity to work on a product that focuses on recreational purposes versus on a daily need. We used the sticky note activity to help hone in on what this opportunity presented.

First, we needed to understand Jenna’s prosthetic leg to understand where the limitations stem from. Her prosthetic has some limitations and does not perfectly mimic an actual human leg. However, it also has some functionality that almost extends the functionality of her prosthetic past that of a sound limb. For example, Jenna’s prosthetic leg has the limitation of having no ankle movement, so the entire leg has to be supported from her residual thigh and microprocessor knee. However, her microprocessor knee has the ability to “lock” in place, so that if she is in a squatting or kneeling position, her knee will lock so that it supports her in that exact position.

To gain a better understanding of the opportunity so that we could design an effective solution, we needed to delve into research before moving ahead. We gained a lot of useful perspective from an ARC yoga instructor, Marsha at Yoga for Amputees, and Jenna herself. From these interviews and discussions, our team was first set on creating a prosthetic foot that Jenna will insert into her microprocessor knee before yoga practice sessions. The initial design included an insertable rod as the main part of the prosthetic and a flipper-like base that would provide Jenna with more support with increased surface area. To visualize the idea, we created a low-fidelity model. As soon as they were created, we met with Jenna to see what her initial thoughts were regarding our prototype. Jenna suggest that we move the rode to the center of the foot rather in the back like a typical leg so that she will have equal support on all sides.

At the same time, we received feedback from Marsha at Yoga for Amputees and she commented that she has seen some prosthetic leg users creating their own DIY “yoga prosthetics”. These users used a base that had more of a “plunger-esque” shape rather than the flipper shape we initially designed. We shared the feedback from Marsha with Jenna and she also confirmed that she believes that a circular base would be the most stable, and having a little suction could provide even more stability when she practices yoga. However, she commented that the suction would have to be weak enough to easily be picked up, as yoga often involves flowing from one position to another. As a result, we created some sketches for a new design based on the feedback.

During this same period, we also met with William, a FUSION 360 expert at MakerLab, and he provided us with sketches that more closely mimics an actual human limb. The sketches created with his assistance had multiple joints that would provide her with more flexibility and movements.

After taking time looking at all of our sketches and low-fidelity models we crafted, we realized that these solutions would only be usable by a small market. A prosthetic replacement could only be used by prosthetic users, which greatly limits the general market of people who have difficulty balancing. The Make-a-Thon introduced us to the residents of Clark Lindsey as potential users and points of inspiration. Thus, during the Make-a-Thon we decided to focus on a more “sandal-eque” product design that will be accessible to a wider range of users in the market versus than just prosthetic limb users that practices yoga. The Clark Lindsey representative that the bathroom is one of the most dangerous rooms in the home regarding falls. Thus, we pictured one scenario that this design could fit in is in bathrooms in front of the sink where elderly people could slip and fall easily and regularly stand for longer periods of time. The design we came up is shown below. We also applied an additional layer of material on the base that provided the shoe with more grip and locks better on to a yoga mat material when practicing yoga.

Soon after Make-a-Thon, we were eager to share and test our product with our mentor. Her reaction to our product was mostly positive as the sandal was able to provide her with more balance than her usual prosthetic. However, the underlying issue was that the sandal could not provide her with any upper calf support. In order to address this, the team decided to abandon our attempt to create a functional product for a larger audience and revert back to our “plunger-esque” prosthetic limb that would cater to specific individual users. Although the target market is smaller, this design could still be very useful for any prosthetic user. This issue is also not being addressed by other designers or companies as we have been able to find through our research, even though there are specific prosthetics for many activities like running and pointe ballet.

We then created a model through FUSION 360 and printed a scaled prototype. Jenna was worried about having that much movement in the “ankle” so we created the file below to print a full scale version for Jenna to test on.

However, when Jenna went to put on the first print, she was not able to insert it into her prosthetic. She realized that the inside of her prosthetic actually was not hollow, and we would need to create a divot for her prosthetic to be able to slide on. We then designed the following file and printed it for her to try out.

Jenna was really happy with the design! The only thing left to do is add some of the cork material that was on the bottom of the additive design to give a touch of height and more traction. We are very happy with the result as well as she said she could definitely feel increased lateral stability and thinks it is a really cool design to have!

You can see our final presentation here.