2015-0411_grayson_portfolio.pptx

DESIGN PORTFOLIO

GRAYSON DAWDY

CONTENTSABOUT ME

33 General Information3 Education4 Work Experience

ACEDEMIC PROJECTS7 Product Development: Ergo-Tool10 Product Design: Bottle Beetle

WORK PROJECTS13 Machine Design: Automated Drilling Station16 Product Development: Cry Baby Mini17 Product Design & Development: PoP Display18 Product Development: Various Products

STARTUP PROJECTS.20 Industrial Design: Self Wrapping Headphones22 Industrial Design Development: Bluetooth Light Switch Cover

OTHER PROJECTS25 Hobby Projects27 Brainstorm: New Bottle Openers

ABOUT ME

Bachelor of Science in Engineering September 2007 – March 2012California Polytechnic State University, California (Cal Poly)

• Concentration: Mechanical and Manufacturing Engineering

• Specialization: Mechanical Design, DFM and DFA

• Studied Abroad: Erasmus Semester in Munich, Germany, 2010

• Favorite Classes: Product Design and Development and Intro to Entrepreneurship

Born: San Francisco, California

Languages: English, Spanish and German

Hobbies: Surfing, Snowboarding, Mountain Biking, Playing Guitar

GENERAL INFORMATION

EDUCATION

GRAYSON DAWDY DESIGN PORTFOLIO - ABOUT ME - 4

WORK EXPERIENCE (I)Alloy Product DevelopmentSan Francisco, California, USASeptember 2014 - PresentMechanical EngineerDesigning and developing products in consumer electronics space

• Projects worked on include wearables and drone technology

• Fast paced, innovative environment• Clients range from top Silicon Valley

companies to new start-ups*Note: Due to the confidential nature of projects at Alloy, I am not allowed to show project details until release.

Self, San Francisco, California, USAFebruary 2014 – September 2014Freelance Mechanical Product Designer:Directly worked with and developed for start-ups in Silicon Valley

• Designed and developed new headphone storing system for Tite-Headphones

• Designed and formulated ID concepts for a smart home devices start-up

• Designed concepts for a start up developing camera scuba diving mounts

• Designed and developed mechanical systems for robotic transportation device

Sketches for Tite-Headphones project


WORK EXPERIENCE (II)Jim Dunlop Musical InstrumentsBenicia, California, USAMarch 2013 – September 2014Mechanical & Manufacturing Engineer:Mechanical engineer for new product team for electronics products

• Designed and developed new electronics enclosures

• Designed and developed automated production machinery

• Worked with production and assembly to incorporate product improvements

Seymour Duncan Guitar Electronics Santa Barbara, California, USAJune 2010 – September 2010July 2011 – September 2011Engineering Intern

• Designed and produced custom guitar electronics for “Custom Shop” based on customer needs

• Completed last phase of product development for new product introduction

Fuzz Face Mini:An example of one of the products I worked on at Dunlop

Blackout Guitar Pickup:An example of some of the type of products made at Seymour Duncan


ACADEMIC PROJECTS

PRODUCT DEVELOPMENT:

Ergo-Tool (I)September 2011 - March 2012

California Polytechnic State UniversityWith Quality of Life Plus ProgramDesign Prompt: Redesign an ergonomic knife

handle (usable without the use of the thumb) to be a handle for different tool attachments. The product must be easily usable, robust and low cost.Inspiration: I researched many existing industrial quick-lock & quick-release systems to help me find a way to quickly lock and secure different tool attachments.Solution: I designed, developed and successfully prototyped a quick-lock & quick-release tooling system to be insert-molded into the ergonomic handle design. My Part: I completed all work on the redesign, including concept ideation, development, analysis and prototyping.

Question: How do you use tools if you don’t have a

thumb?

Design Paths:: Four developed concepts for possible design paths..

Chosen Design Path:

Tools with hexagonal attachments were to be inserted into the

metal base and secured with the

sleeve.

Original Design: Original knife design, which can be used without thumbs...

Sketches: Possible mechanical systems with different user

interfaces.

GRAYSON DAWDY DESIGN PORTFOLIO – ACADEMIC PROJECTS - 8

PRODUCT DEVELOPMENT: Ergo-

Tool (II)Optimize: On the left is the final layout for the geometry. The shape of the sleeve locks the tool insert and keeps it secured.

Analyze: A static state analysis was done on the system to

confirm the robustness of the material choices and wall

thicknesses. Standard aluminum worked well for the system.

Rapid Prototype: A rapid prototype was made to quickly check the system. The prototype led to a change in the sizing of some of the parts to aid the gripping mechanism.

Working Prototype 1: The first working prototype with the

original dimensions. The working prototype worked but lead to

further changes in geometry to increase functionality.

Working Prototype 2: The second prototype had much better functionality. It securely locked the tool in place and easily released it.


PRODUCT DEVELOPMENT: Ergo-

Tool (III)

Ergonomic Handle:Can be gripped, even without the use of thumbs.

Tool Attachments:Different tooling attachments

could now be designed that would only require a hexagonal

base to be used.

Locking base:The large diameter sleeve is easily

pushed back to allow insertion of the tool attachment and easy,

quick release.


PRODUCT DESIGN: Bottle Beetle (I)

September 2011 - December 2011California Polytechnic State University

Design Prompt: In a team of 7, research the needs of small target group and design a product to meet those needs. We focused on users brewing their own beer at home.Research: Through user research from in person interviews and internet forums, we discovered that bottling beer is the most tedious part of brewing beer. After that, internet forums were used to test out ideas and eventually make a design pivot.Solution: To speed up the process of bottling beer, we finally settled on a device to bottle six beers in a standard six-pack configuration.My Part: I was directly involved in the product ideation and concept development stages of the product. I personally created the conceptual renderings and completed user and market research to determine our baseline user group.

The Project Team

Preparation: Research in forums and through

interviews using the IDEO design methodology

Craft Breweries in the USfrom 1976 to 2011: The rise of craft breweries reflects the growing interest in home beer brewing as a growing market.

Data Sources: Brewers Almanac & Brewers

Association


PRODUCT DESIGN: Bottle Beetle (II)

Bottle Beetle:Final design of the beer bottling device

Brainstorming: We worked cohesively as a team and generated concepts through team brainstorms and quick evaluation.

Initial Ideas: Our initial idea was to find a way to fill each bottle more quickly than it was possible before.

Design Pivot: After getting user feedback from our initial brainstorm concepts, we found that it would be more preferable for most users to fill multiple bottles at one time.

Beer flows in from

fermenting barrel.

User inserts and presses the device onto the top of 6 bottles in a standard 6-pack configuration.

Beer flows smoothly into each bottle, filling from

the bottom


WORK PROJECTS

MACHINE DESIGN: Automated Drilling Station

(I)January 2014 – August 2014Used in Production July 2014

Jim Dunlop ManufacturingMachine Concept: The concept of the machine was to quickly drill holes in a painted die cast part.Research: I interviewed factory workers and current machine operators to develop a list of requirements and ergonomic concerns.Solution: I designed, developed and built a machine to quickly drill out a die cast aluminum part (~700/day with one operator). The operator loads the part into the machine, presses the two operating buttons, and the machine will automatically secure the part, cut the hole and clean itself.My Part: I completed all parts of this project, including operator research, mechanical design and development, assembly and programming, and installation with final tweaking.

Machine Purpose: The proposed machine was

to cut holes into this die cast metal part at a rate

of greater than 500 pieces per day.

Initial Machine Sketches: The machine was to be totally automated, the operator would simply have to insert the part and press the two operating buttons.

Calculations: The machine needs to make a balance of forces between the cutting

and holding forces in order to work properly.

GRAYSON DAWDY DESIGN PORTFOLIO – WORK PROJECTS - 14


(II)

Polycarbonate covers

protected the operator from inserting their hand into the machine and

from flying metal chips.

Two ½ horsepower motors spin the drill

part while compressed air it forward.

Materials: All parts were optimized for machining operations. The flat base was made of MIC-6

aluminum, the wear-prone surfaces 4340-Steel, and all other parts made of standard aluminum or

acetal.

Automation: The system was

controlled using a combination of

relays, pneumatic solenoids and a PLC.

Assembly and Programming: The system

was assembled and programmed to optimize

timing for the best operator interaction.



(III)

Operator presses two buttons simultaneously to start the machine.

The machine then automatically clamps the part, cuts the hole and

cleans itself.

Operator loads part into machine.


PRODUCT DEVELOPMENT:Cry Baby Mini

May 2014 - September 2014Product Released January 2015

Jim Dunlop Manufacturing

Product Concept: The Cry Baby Mini is based on a popular guitar effects foot-pedal – the Cry Baby. The aim of this product was to miniaturize the original Cry Baby to make it easier to carry around for gigging musicians.My Part: I generated concepts and developed the mechanical parts of the design. I completed the mechanical analysis of the casing and owned the design of all mechanical parts before release.Release: The product was released at the musical instrument trade show NAMM in January 2015.

Final Product: The Cry Baby Mini is small enough for musicians to carry

around and bring from performance to performance.

Design Audit: I performed the final design audit of the metal and plastic parts before tooling.

Cry Baby Mini in use.


PRODUCT DESIGN & DEVELOPMENT:

Point Of Purchase Display

March 2014 – September 2014Jim Dunlop Manufacturing

Product Concept: A set of display units that would be used to display the wide variety of Dunlop guitar plectrums.My Part: I was involved in generating ID concepts for the initial product with the Graphics and Marketing team at Dunlop. I created the final 3-D models and continued involvement through quoting in prototyping.

Modern StyleClassic Style

Cou

nter

Top

Dis

play

Han

ging

Dis

play

Left: The design was split up into different styles to cover a range of different styles. The product on top were designed to hang objects from hooks, while the products on bottom were designed to hold products in the vacuum-formed plastic tray.


PRODUCT DEVELOPMENT: Various ProductsMay 2014 - September 2014Jim Dunlop Manufacturing

CM95 Guitar Effects Pedal: I completed a redesign of some of the mechanical parts of the pedal to create a better functioning part and deal with manufacturing tolerances.

Fuzz Face Mini Guitar Effects Pedal: I redesigned the rubber portion of the pedal and performed adhesion testing to make sure it stayed put

Echoplex Preamp Guitar Effects Pedal: I owned the mechanical design on this product and was involved with the entire development through to the release.


STARTUP PROJECTS

INDUSTRIAL DESIGN: Self Wrapping Headphones (I)

May 2014 – June 2014Tite Headphones

Product Concept: Tite headphones have a small metal filament that stays wrapped when twisted up. The owner of the start-up wanted me to redesign the cover for the metal filament to be integrated into the plug.My Part: I generated industrial design concepts and developed the most promising concept to be sent out for quotes. The project had a very aggressive timeline.Top : Sketch of the product concept. The idea is that a certain length of the headphone near the plug keeps its shape, so that when it is wrapped up, it stays wrapped.Bottom: Some preliminary sketches for different design paths. Since the entire project had to be done in about 20 hours of work, the initial sketches had only enough information to get the idea across.

Ductile metal filament to be

over-molded into plug protector.

GRAYSON DAWDY DESIGN PORTFOLIO – STARTUP PROJECTS - 21

INDUSTRIAL DESIGN: Self Wrapping

Headphones (II)

To-Scale Sketches:These sketches were the last check

on the design before proceeding straight into a CAD model to be

given to the mechanical engineers.

Final Design:The final design was presented to the client in the form of a 3-D model. The design is now being developed by a

mechanical design group.

Rubber disk insert contains company logo. Allows for easily switchable branding for corporate customers.

ID pattern on base hides flexible filament

and provides mechanical support


INDUSTRIAL DESIGN DEVELOPMENT:

Bluetooth Light Switch Cover (I)Brainstorming: These sketches show some of the

initial concepts for the Bluetooth controlled light switch cover. More details on the next page.


INDUSTRIAL DESIGN DEVELOPMENT:

Bluetooth Light Switch Cover (II)

May 2014 – July 2014Switchmate Ltd

Product Concept: The Switchmate is a Bluetooth controlled light switch cover designed to be put over standard light switch covers. The device is controlled by a mobile phone app that allows the user to program their house lights.My Part: I generated different industrial design concepts and developed the two most promising concepts in 3-D for a concept proposal.

Developed Concept 1: This concept integrates the

electrical assembly into a rectangular covering. A

ring of blue light is programmable around the

inside of the brushed aluminum outer cover. The white portion is covered by

glass to give the user a smooth, tactile feel.

Developed Concept 2: This look gives more of a futuristic feel. Two light pipes running vertically give the user feedback when the product is activated. A smooth, white plastic surface is accented with brushed aluminum on the sides and in the middle.

Inspiration: The mood board on the left was

provided by the client to give inspiration for

the designs.


HOBBY PROJECTS

HOBBY PROJECTS (I)

PRODUCT DESIGN:Bicycle Smart-Phone

Charger March 2014Design Concept: This product was to take the

energy from a spinning bicycle wheel, convert it into electricity and store it in a battery, which was then used to power a smart phone as the user rode his bicycle.

PRODUCT DESIGN:Stylish Home Guitar Amp

March 2014Design Concept: Unlike other guitar amps, which are designed to be carried around from one performance to the next, this amp is designed to be a centerpiece in a modern home or stylish office.

GRAYSON DAWDY DESIGN PORTFOLIO – HOBBY PROJECTS - 26

HOBBY PROJECTS (II)

PRODUCT DESIGN:LIM Guitars

September 2013

Design Concept: The concept was to create a more sustainable guitar: More sustainable wood, recycled metal parts, more earth-friendly electronics and manufacturing processes that create less waste. Unfortunately, the project lost funding before the final first prototype could be made, but the pictures on the left show the initial design on the top and an (unfinished) prototype at the bottom.


BRAINSTORM:New Bottle Opener

July 2015Alloy Product Development

Interview ProcessDesign Prompt: Brainstorm on a new type of bottle opener to improve on the current designs of bottle openers.Background: As part of the interview process at Alloy Product Development, I was asked to brainstorm new types of bottle openers that improved upon the current design of a bottle opener.

INTERVIEW ASSIGNMENTS: ALLOY PD (I)

Brainstorming: Different ideas for new types of bottle openers. The top left ideas are electric, the top right use mechanical advantage, the bottom left are simple improvements on the bottle opener, and the bottom right shows a storage system that opens bottles as you remove them.


INTERVIEW ASSIGNMENTS: ALLOY PD (II)Light Up Amulet Design

July 2015Alloy Product Development

Interview ProcessDesign Prompt: Create a product to show my mechanical design skills in one week before the in-person interview.Background: As part of the interview process at Alloy Product Development, I decided to create a light up amulet especially to demonstrate my mechanical design skills. I decided to make a 50mm by 50mm amulet that was lit up with a small tactile switch.

Initial Brainstorming

Modeled AssemblyStress analysis on

screw forces during assembly

Final printed assembly,

front and back

Amulet lights up the Alloy logo in the darkness.


END OF PORTFOLIO

2015-0411_grayson_portfolio.pptx

Documents

mechanical design

tool10product design

phase of product development

new product team

california languages

custom guitar electronics

mechanical systems

new headphone