Mudgeeraba Special School Student
Design Problem.
“From one of your family members, relative or family friend, identify a personal need which exists within or around their living environment. Identify, design, fabricate and evaluate a solution to this need, which meets the personal requirements of that individual.”
The task is to design a solution that will accommodate for the needs of a Mudgeeraba Special School Student. The area of the problem is an indoor classroom, with special needs students, the environment is controlled so there will be no need to consider outside weather considerations such as rust. There are few constraints other than time, size and price of the chair. The time constraint is a semester, and the chair must fit the student who is in year 1, the chair …show more content…
will mimic the chair that is already in use at the school, but also be slightly modified (Picture 1). The price point that we aim to accomplish is that it will be under $500. The chair that is already in use is used for students in higher grades; it will be shrunk to size for a year one student. Problem has been originated from a request from Lyn Campbell, who is a teacher at the school. It would be a big help if they had more chairs like it.
Design Factors
The following design factors will be used in solving this design task.
User Centred design
The atypical student is 6 years and has cerebral palsy disability. The needs of the students for this chair is very apparent as the chair will help them sit up straight due to them not having the physical ability to hold themselves up. The comfortably of the chair is just needed for periods of how long a class is. The chairs are very accessible due to the student needing it to learn. Chair has to have the ergonomics to prop the student up on the chair and allow them to write, read and interact in class. The chair mustn’t collapse while holding an individual, the chairs vinyl seats allow biological messes to be cleaned up.
Sustainable design
The chair must be sustainable as the student will be using these chairs every day for their needs.
The sustainability of the design will economical as the chair will be made of steel, the chair will be designed to be built to last. Over the years it is used it will provide its value
• Durability of material.
• Coatings used to protect the material from oxidisation (rust)
• Re usable materials
• Strength of joins used
Elements and principles of design
The design will be predominantly grey and blue in colour, shape of the chair will be rectangular and squared.
Communication
Can be communicated through pictures of the existing design and annotated sketches Legal responsibilities
The legal responsibilities are known that it will be used in schools. It must be stable, strong and durable, and resistant to heat, liquid and mechanical damage. The chair must be allergen free.
Manufacturing technologies
The size, shape and finish is not going to be altered. The tools that will be used will be: MIG welder, magnetic right angle, bandsaw, hand saw, file, angle grinder, spray adhesive, sandpaper and scissors
Materials
Materials that will be used is plywood, steel posts, foam, plastic …show more content…
vinyl.
Plywood is inexpensive and easily replaceable if broken. The way plywood can be joined is by cutting notches like dove tails and join them in by glue and friction, another way would be to screw or nail them together. The weight of the materials is not required as there will be only be a small portion of it on the chair itself. The plywood is strong and can bend under loads. Plywood can be sanded and then be applied with paint or lacquer.
Steel rectangular tubing are inexpensive but can hold a lot of weight. Steel itself is heavy. The ways in joining steel together is by welding two together to from one. Steel can be sanded, polished, lacquered and painted.
Foam is quite squashy and can be used to soften areas of rooms or used as chair cushions. The cost of this foam is very inexpensive and its weight is minimal. Joining foam to other materials would work buy gluing one to the other.
Plastic vinyl can be stretched and moulded to any contour; this means it would be the cover for the foam. This material is inexpensive and widespread. Due to it being plastic, it can easily be wiped down if any mess were to be on it.
Project management skills
Allocating time frames to finish a task as efficiently and safely as possible. To also allocate budgets for specific tasks i.e. cushions, frame etc.
Design strategies
Looking at existing designs and other areas that may inspire. i.e. a spring for and armrest.
Clarification and research
Client
The client is Mudgeeraba Special School; they require more learning instruments for their students, but the instruments i.e. the chair cost around about $900 with other optional bits like a headrest and foot rests. Another problem is that these specific chairs are designed for year 1 students, which are 5/6 years old. The students also have mental and physical disabilities.
Environment
The area in which the chair is used will be in a classroom which will be isolated from the weather so there is no need to consider oxidation of the steel. The chair will be used for a majority of the day so it is crucial that they are built to last.
Other Constraints
The time constraint is that it has to be down by next term, must fit a year 1 student, and to minimise cost as much as possible. The manufacturing process will be limited to tools available in the workshop, and the skills needed for those tools.
Design Brief
The design brief is creating a chair for a typical student who is in year one. But reduce the cost of it, as a third party retail price for the chair is more expensive than it should be. The factors for the design are that it must be suited for a typical student in the Mudgeeraba special school. They will also need to be reusable and built to last for economic reason. It is also a factor to minimise the cost of production.
Inspiration
Specifications
Constraints
• Must fit client who is in grade 1
• Must be economical to make, aiming to make the chair for under $500
• Must assist the client’s disabilities
Considerations
Considerations would to include the textile of the cushion, colour of the chair and
Limitations
There will be limitations in skill level, material, tools and budget.
EVALUATION criteria
Please Tick Yes No
Is the Quality of the build good?
Is the comfortability of the build good?
Does the size of the build suit the client?
Does the build match the design brief
Any other Feedback Materials were great, upholstery of armrests/backrests very easy to clean. Frame of chair welded securely and very stable
Perhaps consider adding a plastic / rubber cap to the bottom of chair legs so that it doesn't damage floors. You have both done a fantastic job, well done!
Developing Design Ideas.
Producing a Product Solution
Part No. Name Quantity Material Dimensions Estimated Cost Safety
1 Seat Cushioning 1 Foam Length= 295mm
Width= 295mm
Height= 80mm $12/320mm x 320mm
Approx.= $10.08 Safety Spectacles
2 Seat support 1 Plywood Length= 295mm
Width= 295mm
Height= 10mm $20/ 897mm x 600mm
Approx.= $3.20 Safety Spectacles
3 Back Rest cushioning 1 Foam Length= 265mm
Width= 140mm
Height= 80mm $12/320mm x 320mm
Approx.= $4.32 Safety Spectacles
4 Back rest Support 1 Plywood Length= 265mm
Width= 140mm
Height= 10mm $20/ 897mm x 600mm
Approx.= $1.20 Safety Spectacles
5 Arm rest Cushioning 2 Foam Length= 230mm
Width= 70mm
Height= 80mm $12/320mm x 320mm
Approx.= $3.72 Safety Spectacles
6 Arm rest Support 2 Plywood Length= 230mm
Width= 70mm
Height= 10mm $20/ 897mm x 600mm
Approx.= $1 Safety Spectacles
7 Seat Frame Sides 2 Steel R.T. Length= 280mm
Width= 30mm
Inside Width= 27mm $3.28/m
Approx.= $.91 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
8 Seat Frame Front and back 2 Steel R.T. Length= 250mm
Width= 30mm
Inside Width= 27mm $3.28/m
Approx.= $.82 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
9 Legs 4 Steel R.T. Length= 155mm
Width= 30mm
Inside Width= 27mm $3.28/m
Approx.= $.50 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
10 Inner Legs 4 Steel R.T. Length= 140mm
Width= 24mm
Inside Width= 23mm $2.66/m
Approx.= $.37 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
11 Back rest 2 Steel R.T. Length= 300mm
Width= 30mm
Inside Width= 27mm $3.28/m
Approx.= $.98 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
12 Back rest frame support 2 Steel R.T. Length= 198mm
Width= 30mm
Inside Width= 27mm $3.28/m
Approx.= $.64 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
13 Arm rest T-Join Part 1 2 Steel R.T. Length= 100mm
Width= 30mm
Inside Width= 27mm $3.28/m
Approx.= $.32 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
14 Arm rest T-Join Part 2 2 Steel R.T. Length= 100mm
Width= 30mm
Inside Width= 27mm $3.28/m
Approx.= $.32 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
15 Arm rest T-Join inner 2 Steel R.T. Length= 120mm
Width= 24mm
Inside Width = 23mm $2.66/m
Approx.= $.31 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
16 Bracket 2 Steel R.T. Length= 100mm
Width= 30mm
Inside Width= 27mm $3.28/m
Approx.= $.32 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
17 Seat-under support 2 Steel R.T. Length= 300mm
Width= 30mm
Inside Width= 27mm $3.28/m
Approx.= $.32 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
18 Backrest Vinyl 1 Vinyl. Length= 408mm
Width= 219mm $28/1.4mx1.6m
Approx.= $7 Safety Spectacles
19 Seat Vinyl 1 Vinyl Length= 454mm
Width= 454mm $28/1.4mx1.6m
Approx.= $2.8 Safety Spectacles
20 Arm Rest Vinyl 2 Vinyl Length= 455mm
Width= 320mm $28/1.4mx1.6m
Approx.= $8.4 Safety Spectacles
21 Star knobbed hand bolt 4 Plastic/ steel Thread= M8
Length = 20mm $3/bolt
Approx.= $12 Safety Spectacles Approximate total
= $58.57
Process No. Action Process Time
1 Cutting Steel R.T. to specific lengths On the metal cutting bandsaw, cutting specific lengths 2 – 3 Hours
2 Cutting Plywood Cutting plywood on the bandsaw, to specific lengths .5 Hours
3 Cutting Foam Cutting foam on the bandsaw, to specific lengths .5 Hours
4 Gluing Plywood to foam Gluing with spray adhesive foam to the plywood .5 Hours
5 Sizing Vinyl Sizing vinyl by making a prototype in butchers paper 1hr
6 Cutting vinyl Cutting vinyl with scissors to length of prototype .5 Hours
7 Stapling Stapling the vinyl to the plywood to make the final cushion .5 Hours
8 Drilling holes Holes for button adjustment and screw adjustment 1 hour
9 Adding the button Adding the button adjustment by welding tensile steel back of each leg .5
10 Tap and dye Creating a screw hole for the arm adjustments .5
11 Welding R.T. Welding R.T. to each other. First a tack in two places, then welded along the join 2-3 hours
12 Grinding Joins Grinding the welded joins until bump is minimal 1 Hour
13 Priming the frame Paint the frame with 4 coats primer 24 Hours
14 Painting After primer has dried paint with 5 coats of hammered finish paint 24 hours
15 Done 58.5 hours/ 2.43 days
Evaluating the Product Solution
Project Evaluation
Although the prototype is incomplete, it already demonstrates its ability to help the student sit up straight by having the backrest and arms supporting them.
The chair would definitely not be able to collapse under the weight of the student due to it being welded extremely strong to each individual part. The steel rectangular tubing is extremely durable especially when welded together. The steel is already galvanised, but once welded the galvanised is oxidised leaving the metal unprotected. To combat this and give the chair a bit personality, instead of bare steel the chair is primed and painted with hammered finish spray
paint.
The colour of the armrest, seat and backrest are blue vinyl. In addition, the chair is painted in a hammered finish. Legally it must be able to sustain the constant weight of the user and be allergy free. MIG welder, magnetic right angle, bandsaw, handsaw, file, angle grinder, spray adhesive, sandpaper and scissors were all used in the process of making the prototype.
Plywood, steel rectangular tubing, foam and plastic vinyl were incorporated into the prototype.
There were no modifications from the proposal to the prototype. Improvements would defiantly be the skill of welding and the quality of the welds. Others would be incorporating a tray that folds onto the lap of student. This tray would be connected and solely supported by the chair and actually not the student. The procedure of the manufacturing phase was pretty messy going back and forth because some things were an oversight, or neglected as a minimal part of the project but turned out quite hard to do. For example upholstering the cushions were quite difficult.
There were many mistakes, the welds bending the steel due to the heat from the weld to make it expand and then contract. Another mistake was forgetting to use a tri-square to make right angles in welding, this had to be touched up in the end by sawing through the metal until 10mm was left and then bending that metal until it was 90o, and then re-welded.
“From one of your family members, relative or family friend, identify a personal need which exists within or around their living environment. Identify, design, fabricate and evaluate a solution to this need, which meets the personal requirements of that individual.”
The task is to design a solution that will accommodate for the needs of a Mudgeeraba Special School Student. The area of the problem is an indoor classroom, with special needs students, the environment is controlled so there will be no need to consider outside weather considerations such as rust. There are few constraints other than time, size and price of the chair. The time constraint is a semester, and the chair must fit the student who is in year 1, the chair …show more content…
will mimic the chair that is already in use at the school, but also be slightly modified (Picture 1). The price point that we aim to accomplish is that it will be under $500. The chair that is already in use is used for students in higher grades; it will be shrunk to size for a year one student. Problem has been originated from a request from Lyn Campbell, who is a teacher at the school. It would be a big help if they had more chairs like it.
Design Factors
The following design factors will be used in solving this design task.
User Centred design
The atypical student is 6 years and has cerebral palsy disability. The needs of the students for this chair is very apparent as the chair will help them sit up straight due to them not having the physical ability to hold themselves up. The comfortably of the chair is just needed for periods of how long a class is. The chairs are very accessible due to the student needing it to learn. Chair has to have the ergonomics to prop the student up on the chair and allow them to write, read and interact in class. The chair mustn’t collapse while holding an individual, the chairs vinyl seats allow biological messes to be cleaned up.
Sustainable design
The chair must be sustainable as the student will be using these chairs every day for their needs.
The sustainability of the design will economical as the chair will be made of steel, the chair will be designed to be built to last. Over the years it is used it will provide its value
• Durability of material.
• Coatings used to protect the material from oxidisation (rust)
• Re usable materials
• Strength of joins used
Elements and principles of design
The design will be predominantly grey and blue in colour, shape of the chair will be rectangular and squared.
Communication
Can be communicated through pictures of the existing design and annotated sketches Legal responsibilities
The legal responsibilities are known that it will be used in schools. It must be stable, strong and durable, and resistant to heat, liquid and mechanical damage. The chair must be allergen free.
Manufacturing technologies
The size, shape and finish is not going to be altered. The tools that will be used will be: MIG welder, magnetic right angle, bandsaw, hand saw, file, angle grinder, spray adhesive, sandpaper and scissors
Materials
Materials that will be used is plywood, steel posts, foam, plastic …show more content…
vinyl.
Plywood is inexpensive and easily replaceable if broken. The way plywood can be joined is by cutting notches like dove tails and join them in by glue and friction, another way would be to screw or nail them together. The weight of the materials is not required as there will be only be a small portion of it on the chair itself. The plywood is strong and can bend under loads. Plywood can be sanded and then be applied with paint or lacquer.
Steel rectangular tubing are inexpensive but can hold a lot of weight. Steel itself is heavy. The ways in joining steel together is by welding two together to from one. Steel can be sanded, polished, lacquered and painted.
Foam is quite squashy and can be used to soften areas of rooms or used as chair cushions. The cost of this foam is very inexpensive and its weight is minimal. Joining foam to other materials would work buy gluing one to the other.
Plastic vinyl can be stretched and moulded to any contour; this means it would be the cover for the foam. This material is inexpensive and widespread. Due to it being plastic, it can easily be wiped down if any mess were to be on it.
Project management skills
Allocating time frames to finish a task as efficiently and safely as possible. To also allocate budgets for specific tasks i.e. cushions, frame etc.
Design strategies
Looking at existing designs and other areas that may inspire. i.e. a spring for and armrest.
Clarification and research
Client
The client is Mudgeeraba Special School; they require more learning instruments for their students, but the instruments i.e. the chair cost around about $900 with other optional bits like a headrest and foot rests. Another problem is that these specific chairs are designed for year 1 students, which are 5/6 years old. The students also have mental and physical disabilities.
Environment
The area in which the chair is used will be in a classroom which will be isolated from the weather so there is no need to consider oxidation of the steel. The chair will be used for a majority of the day so it is crucial that they are built to last.
Other Constraints
The time constraint is that it has to be down by next term, must fit a year 1 student, and to minimise cost as much as possible. The manufacturing process will be limited to tools available in the workshop, and the skills needed for those tools.
Design Brief
The design brief is creating a chair for a typical student who is in year one. But reduce the cost of it, as a third party retail price for the chair is more expensive than it should be. The factors for the design are that it must be suited for a typical student in the Mudgeeraba special school. They will also need to be reusable and built to last for economic reason. It is also a factor to minimise the cost of production.
Inspiration
Specifications
Constraints
• Must fit client who is in grade 1
• Must be economical to make, aiming to make the chair for under $500
• Must assist the client’s disabilities
Considerations
Considerations would to include the textile of the cushion, colour of the chair and
Limitations
There will be limitations in skill level, material, tools and budget.
EVALUATION criteria
Please Tick Yes No
Is the Quality of the build good?
Is the comfortability of the build good?
Does the size of the build suit the client?
Does the build match the design brief
Any other Feedback Materials were great, upholstery of armrests/backrests very easy to clean. Frame of chair welded securely and very stable
Perhaps consider adding a plastic / rubber cap to the bottom of chair legs so that it doesn't damage floors. You have both done a fantastic job, well done!
Developing Design Ideas.
Producing a Product Solution
Part No. Name Quantity Material Dimensions Estimated Cost Safety
1 Seat Cushioning 1 Foam Length= 295mm
Width= 295mm
Height= 80mm $12/320mm x 320mm
Approx.= $10.08 Safety Spectacles
2 Seat support 1 Plywood Length= 295mm
Width= 295mm
Height= 10mm $20/ 897mm x 600mm
Approx.= $3.20 Safety Spectacles
3 Back Rest cushioning 1 Foam Length= 265mm
Width= 140mm
Height= 80mm $12/320mm x 320mm
Approx.= $4.32 Safety Spectacles
4 Back rest Support 1 Plywood Length= 265mm
Width= 140mm
Height= 10mm $20/ 897mm x 600mm
Approx.= $1.20 Safety Spectacles
5 Arm rest Cushioning 2 Foam Length= 230mm
Width= 70mm
Height= 80mm $12/320mm x 320mm
Approx.= $3.72 Safety Spectacles
6 Arm rest Support 2 Plywood Length= 230mm
Width= 70mm
Height= 10mm $20/ 897mm x 600mm
Approx.= $1 Safety Spectacles
7 Seat Frame Sides 2 Steel R.T. Length= 280mm
Width= 30mm
Inside Width= 27mm $3.28/m
Approx.= $.91 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
8 Seat Frame Front and back 2 Steel R.T. Length= 250mm
Width= 30mm
Inside Width= 27mm $3.28/m
Approx.= $.82 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
9 Legs 4 Steel R.T. Length= 155mm
Width= 30mm
Inside Width= 27mm $3.28/m
Approx.= $.50 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
10 Inner Legs 4 Steel R.T. Length= 140mm
Width= 24mm
Inside Width= 23mm $2.66/m
Approx.= $.37 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
11 Back rest 2 Steel R.T. Length= 300mm
Width= 30mm
Inside Width= 27mm $3.28/m
Approx.= $.98 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
12 Back rest frame support 2 Steel R.T. Length= 198mm
Width= 30mm
Inside Width= 27mm $3.28/m
Approx.= $.64 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
13 Arm rest T-Join Part 1 2 Steel R.T. Length= 100mm
Width= 30mm
Inside Width= 27mm $3.28/m
Approx.= $.32 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
14 Arm rest T-Join Part 2 2 Steel R.T. Length= 100mm
Width= 30mm
Inside Width= 27mm $3.28/m
Approx.= $.32 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
15 Arm rest T-Join inner 2 Steel R.T. Length= 120mm
Width= 24mm
Inside Width = 23mm $2.66/m
Approx.= $.31 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
16 Bracket 2 Steel R.T. Length= 100mm
Width= 30mm
Inside Width= 27mm $3.28/m
Approx.= $.32 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
17 Seat-under support 2 Steel R.T. Length= 300mm
Width= 30mm
Inside Width= 27mm $3.28/m
Approx.= $.32 Safety Spectacles gloves, welding jacket, apron, gloves & Mask
18 Backrest Vinyl 1 Vinyl. Length= 408mm
Width= 219mm $28/1.4mx1.6m
Approx.= $7 Safety Spectacles
19 Seat Vinyl 1 Vinyl Length= 454mm
Width= 454mm $28/1.4mx1.6m
Approx.= $2.8 Safety Spectacles
20 Arm Rest Vinyl 2 Vinyl Length= 455mm
Width= 320mm $28/1.4mx1.6m
Approx.= $8.4 Safety Spectacles
21 Star knobbed hand bolt 4 Plastic/ steel Thread= M8
Length = 20mm $3/bolt
Approx.= $12 Safety Spectacles Approximate total
= $58.57
Process No. Action Process Time
1 Cutting Steel R.T. to specific lengths On the metal cutting bandsaw, cutting specific lengths 2 – 3 Hours
2 Cutting Plywood Cutting plywood on the bandsaw, to specific lengths .5 Hours
3 Cutting Foam Cutting foam on the bandsaw, to specific lengths .5 Hours
4 Gluing Plywood to foam Gluing with spray adhesive foam to the plywood .5 Hours
5 Sizing Vinyl Sizing vinyl by making a prototype in butchers paper 1hr
6 Cutting vinyl Cutting vinyl with scissors to length of prototype .5 Hours
7 Stapling Stapling the vinyl to the plywood to make the final cushion .5 Hours
8 Drilling holes Holes for button adjustment and screw adjustment 1 hour
9 Adding the button Adding the button adjustment by welding tensile steel back of each leg .5
10 Tap and dye Creating a screw hole for the arm adjustments .5
11 Welding R.T. Welding R.T. to each other. First a tack in two places, then welded along the join 2-3 hours
12 Grinding Joins Grinding the welded joins until bump is minimal 1 Hour
13 Priming the frame Paint the frame with 4 coats primer 24 Hours
14 Painting After primer has dried paint with 5 coats of hammered finish paint 24 hours
15 Done 58.5 hours/ 2.43 days
Evaluating the Product Solution
Project Evaluation
Although the prototype is incomplete, it already demonstrates its ability to help the student sit up straight by having the backrest and arms supporting them.
The chair would definitely not be able to collapse under the weight of the student due to it being welded extremely strong to each individual part. The steel rectangular tubing is extremely durable especially when welded together. The steel is already galvanised, but once welded the galvanised is oxidised leaving the metal unprotected. To combat this and give the chair a bit personality, instead of bare steel the chair is primed and painted with hammered finish spray
paint.
The colour of the armrest, seat and backrest are blue vinyl. In addition, the chair is painted in a hammered finish. Legally it must be able to sustain the constant weight of the user and be allergy free. MIG welder, magnetic right angle, bandsaw, handsaw, file, angle grinder, spray adhesive, sandpaper and scissors were all used in the process of making the prototype.
Plywood, steel rectangular tubing, foam and plastic vinyl were incorporated into the prototype.
There were no modifications from the proposal to the prototype. Improvements would defiantly be the skill of welding and the quality of the welds. Others would be incorporating a tray that folds onto the lap of student. This tray would be connected and solely supported by the chair and actually not the student. The procedure of the manufacturing phase was pretty messy going back and forth because some things were an oversight, or neglected as a minimal part of the project but turned out quite hard to do. For example upholstering the cushions were quite difficult.
There were many mistakes, the welds bending the steel due to the heat from the weld to make it expand and then contract. Another mistake was forgetting to use a tri-square to make right angles in welding, this had to be touched up in the end by sawing through the metal until 10mm was left and then bending that metal until it was 90o, and then re-welded.