Belfast Product Design: CAD, Prototyping and Engineering
Generating new product design concepts, developing prototypes and delivering production designs
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Consumer

This consumer product case study provides an excellent example of how the design process delivers great results. Staring off with a well defined problem, concept solutions were generated and prototypes used to verify performance. After the concept has been agreed, CAD models are used to engineer and refine the product and create a manufacturing design.

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CONSUMER PRODUCT DEVELOPMENT

CASE STUDY :

BULLY WETSUIT WASHER

Completed while Project Manager at IDC (creds)

An innovative new product for washing wetsuits after use. Increasing convenience and providing more effective cleaning, this wetsuit washing system is economic to manufacture and engineered to reduce water use. A striking visual identity and anthropometric form provide strong user appeal.

 
“The best experience we’ve known till today.
Ryan dedicated his full attention, patience and professionalism to every single thing along the way and we got a perfect product! As we always dreamed!
”
— Maor Dayan, Founder of MAS Bully
 
 
 
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CONCEPT SKETCHES

Initial sketches were used to explore both the overall product identity and important design elements. Further conceptual refinement was then considered through colour, material and surface finish. The overall form of the product was dictated by the wash requirements and strong visual identity was achieved through the use of angled structural supports.

 
 
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3D CAD MODEL

After preliminary experimental testing was completed, the detailed design of individual components was developed in 3D CAD software (SolidWorks). Review of the full assembly ensured that reliable and cost effective manufacturing was achieved. The exploded assembly shows the simple moulded plastic construction methods and water piping arrangement.

 
 
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PROTOTYPE TESTING

Various water flow patterns, hole distributions and flow orifice sizes were evaluated to determine the most effective washing solution across a range of inlet pressures. Designed to work “out of the box” the product was fitted with a quick-lock hose connector and a robust hook for hanging.

 
 
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MANUFACTURING PROTOTYPE

A number of fully working manufacturing prototypes were constructed for experimental evaluation and product marketing activities. Initial feedback revealed the requirement for a collar support to be added prior to mass manufacture to cater for the widest range of wetsuits.

 
 
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FINAL PRODUCT

The final product was launched at the World Surf Championships in Portugal to widespread acclaim. The eye-catching design was made available in a range of colours to provide customers with additional customisation at premium pricing.