Binder1

DANNY ESSOM
-
INDUSTRIAL DESIGN
PORTFOLIO

Personal Speaker
Conicurl
Injection Mould Tool
Your Island
Comfi
Kasenvy
About Me

Using Industrial design tools
to develop a highly attractive
audio product which can
house a pre-assembled
speaker system and PCB. The
speaker can be assembled with
injection moulding and then
easily assembled along with the
standard components to deliver a
highly desirable final product.
The product was developed by
producing a surface model of the
final design and then splitting it
into it’s different components. This
ensures an accurate final assembly
which can be used to produce
high definition renders to display
the concept.

To develop the final concept
research was carried out to
discover the most popular
current trends to ensure that the
final concept was as desirable
as possible. These key trends
included Modern, Minimilistic
styles. Concept sketching then
allowed different forms to be
explored to ensure that the right
aestheti was found.
The final design features a
streamlined aesthetic with some
clean edges to add to the shape.
It uses modern materials and a
minimalist colour scheme to leave
a beautiful final product.

ConiCurl is a redesign of the Mark
Hill Hot Air Styler. A hair dryer
with added bush which produces
extra volume in the users hair
allowing them to consistently
produce the style they’re after. The
original product features a thick
body which was very difficult to
operate, resulting in a product
that caused the user stress whilst
attempting to simplify their hair
routine.
The new design aims to provide a
much more ergonomic operation
whilst appearing much more
premium and remaining in touch
with the brand.

To develop the new design, the
original product was disassembled
to determine the key components
that must remain. This was then
used as an underlay to produce a
number of concepts which could
enhance the users experience. The
original product used a number
of heads to provide different sizes
of volume. To get around this
a tapered head was developed
which would give the user variety
in volume by moving along
the brush The difficult to reach
buttons were also moved to a
simple wheel and trigger format
to ease operation.

Designing and manufacturing an
operational injection mould tool
that would effectively produce
the desired product. Then
determining how the injection
mould tool could be upscaled
to produce a supply model that
would produce 3 million products
over 3 months.
The initial tool design was
developed to produce drawings
which could then be used in the
manufacturing of the mould tool.

4 cavities with a total cycle
time of 9.97seconds
Total production time of
12wks 6days 20hrs 56mins 15secs
By using Material specific software
(CES) the ideal polymer type could
be selected (LDPE). By timing
how long it takes to inject a single
mould we could determine the
duration to completely deliver
the product in a series of four
moulds. To determine the best
point of injection in the cavities,
flow simulation was used within
Solidworks to reduce the risk of
shrinkage during cooling.
5.3p per 4 moulded items
£89,000 overall production cost
(exc. Bills)
Hold Time 0.32s
(3%)
Fill Time 0.32s
(30%)
Freeze Time 2.9s
(29%)
Insert Change Over 1.5s
(15%)
Fill Time 0.4s
(4%)
83 tons of LDPE to create
3million widgets
Hold Time 0.2s
(2%)
Freeze Time 0.7s
(7%)
Mould Opening Time 0.4s
(4%)
Ejection Time 0.2s
(2%)
Mould Closing Time 0.4s
(4%)

For manufacturing of the mould
tool, the two halves were CNC
machined from a program
developed in Creo. And trialed in
blue foam to ensure success on
the final aluminium material. Each
insert was then manufactured on
a variety of equipment including
vertical milling machines and
centre lathes.
The whole process took around a
month to manufacture from start
to finish resulting in a successful
final product.

Your Island is a energy saver app
which is designed to encourage
families to act upon their
energy usage through subtle
gameification techniques. The
basis of the app is your character
‘Johnny Polar Bear’ which works
with the house smart meter. The
island on which your character
stands will shrink or expand
depending on the current energy
usage. This provides a real time
view of the impact the house
is having on the environment
through the condition of their
character.
The app features a community
page which can be linked to social
media to see how the house is
doing compared to their friends
to further encourage them to
improve their habits.

The apps development began
with research into different
effective gameifitcation points
which would guarantee the users
commitment to the app.
Next, simple wireframe’s were
used alongside a range of user
tests to determine the navigation
to optimise the user experience.
These user tests had involvement
from various ages (parents and
children) to confirm that the app
would easy to use by the whole
family.

The final app was developped into
a working prototype that allowed
the user to operate the whole app.
The content of the app featured
not only pages depicting the users
energy usage. But clear graphics
showing which appliances were
using the most energy, a clear
breakdown of their past energy
usage and how they could
improve their consumption.
Users would then gain points
faster when they had a better
energy score and could spent
these points on customiseable
gifts for their character, or real
world prizes to spend on the
whole family.

One of the largest occupier of time
on the NHS is regular check-ups
of longterm cancer sufferers. It’s
not uncommon for them to have
to visit their doctors on a regular
basis to have blood pressure
checks to keep record on progress.
Comfi is a home blood presure
device, connected directly to the
patients doctor via a dedicated
app. The patient can easily record
their results, send to their doctor,
and can be contacted if further
attention is required.

The product was developed
through extensive concept
sketching and research to ensure
the most effecient user experience
possible. This included avoiding
excessive technology such as
touch screen to ensure that
unwell, and elderly users could
operate the product with minimal
stress.
The final design delivers an
effective solution to allowing
patients to deliver essentiel results
to doctors whilst causing little
distress to the user by avoiding
the need to leave the comfor t of
their own home and taking up
essential time that could be used
on another patient.

Kasenvy is my own brand of
iPhone cases which involved me
creating the graphics and liasing
with a supplier to develop a high
quality product. I then designed
and sourced packaging to go with
the product to ensure a premium
product. I spent time developing
the website and establishing a
social media presence with regular
blog and product updates.

Self built E-commerce website
responsive to all browsers
15 Design Options
High Quality Material
Accompanying Blog and Social
Media pages
Self Branded, High Quality
Packaging

Experience:
Industrial Design & Technology 2014-18
JDE - Industrial Design Intern 2016-17
Kasenvy Designer and Owner 2014-16
Engineering Education Scheme 2012-13
Contact:
d.essom@icloud.com
07585553869