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Webcast Marks World Industrial Design Day

Industrial Design - Global markets, local solutions

This major day has been introduced by the International Council of Societies of Industrial Design (Icsid), ‘in order to raise awareness about the benefits of industrial design in improving our quality of life.’ IDC’s webcast will mark it by discussing the globalisation of product design, understanding the cultural and commercial subtleties of international markets and how the designer’s insights can contribute in a meaningful, sustainable, and commercially successful way.

The webcast will take place on WIDD, Monday 29th June at 9am GMT. To find out more and register, visit www.idc.uk.com

For more information about WIDD and Icsid, log on to www.icsid.org

19 June 2009

IDC Outlines Merits of Plastics in Design at PMD

IDC projects director, Brian Gough, delivered a key presentation at this year’s Plastics in Medical Devices (Brussels, May 2009), suggesting that the design opportunities offered by plastics are almost infinite - providing you ask the right questions from the outset.

The presentation highlighted a range of factors affecting plastics choice in design when developing a world class medical device. Addressing the essential issues of device application and risk classification, as well as regulation, testing and compliance, Gough drew on several award-winning medical products designed by IDC to illustrate how to tackle the central points in the process.

IDC’s multi-award winning insulin pen designed for Indian healthcare giant Wockhardt, provided a strong insight into the process. With diabetes a significant problem in India, Wockhardt was able to supply insulin but lacked a cost effective way to administer it. The company needed both a disposable and reusable injector pen each made from 100% plastic, which would meet stringent international regulations (ISO/FDA), testing and compliance, and also side-step existing patents without compromising on quality.

“As with all medical device projects, understanding a product’s purpose and function, and identifying competing products in the marketplace is vital. What sort of weight and strength is required for durability? Are there specific or unusual aspects of mechanical performance to be met? Will it need to be resistant to oils, UV, solvents, radiation? The question of the device’s classification is the next issue, raising questions over sterility and additional concerns from cleanliness in manufacture to infection control and bacterial barrier properties, depending on how and where the devise is used. All these factors, as well as tooling and manufacture, affect polymer choice for the designer,” said Gough.

Before embarking on the insulin pen design, IDC examined the market and user needs, isolating and analysing competitor products and their regulatory requirements. Engineers and designers reviewed over 150 patents, 30 competitor products and their functional mechanisms, as well as the requirements of international standards. They also conducted user interviews and discussed the product with GPs.

IDC’s in-house Viper SLA machine provided a prototype for verification and accuracy, which could then be taken to TNO for initial opinion and guidance to obtain a medical CE mark. In total, 15 plastics were used, each carefully selected on the basis of mechanical, chemical, aesthetic and functional properties, as well as cost.

Gough continues, “The application and level of invasiveness of any given medical device will naturally affect the polymer choice, verification and manufacture process – and the overall cost. But it’s important to remember that just because a device is medical, doesn’t mean it necessarily needs a medical grade material.”

Other IDC case studies discussed which use plastics in medical design included:

- The world’s first non-invasive Medick Personal Heart Monitor from concept to production (class 1) developed and launched within 6 months

- The ZYDUS CADILA Asthma Inhaler (class 2a). Millions sold across India

- The Vielle Stimulator for women with sexual dysfunction. Awarded The Design Effectiveness Award for consumer product (class 1)

- The Venner LoTrach™ Cuff Pressure Controller (CPC) for monitoring and controlling the inflation pressure of LMA LoTrach™ Endotracheal and Tracheostomy tubes (class 2a)

In conclusion, Gough explained, “One thing is absolute: the use of plastics in today’s medical devices opens many doors in terms of design, but it is only through an accurate and in-depth understanding of polymers in the context of medical classification and the corresponding regulations that superior quality products can be designed.”

19 June 2009

IDC Designs Awards for UK Tour Series

Tasked by the organisers of The Tour of Britain and The Tour Series, SweetSpot Group Ltd., IDC’s model making specialists and product designers have collaborated to develop a unique trophy design. IDC is very familiar with the detailed product development process involved in creating an award. The company recently worked with New Pro Foundries on the high profile film and television award, BAFTA.

Vincent O’Horo, Director of IDC Models, explains, “The Tour Series is a fantastic set of ten events which sees a return to competitive cycling in Britain’s towns and cities. As a new Series, we needed to produce an award that would be instantly recognizable and in line with the brand itself so that it would become iconic in the cycling world.”

The product design incorporated the brand’s flagman and shield motif, curved surfaces and aluminium stands inspired by the design of cycle fittings and accessories. Translating this into a 3D form required the evolution of the logo to accommodate production techniques.

The project drew on several in-house disciplines, from design and engineering to rapid prototyping techniques, CNC, specialist model making and short run manufacture. The product designer’s Viper SLA (stereolithography) machine speeded up the process by producing same-day prototypes. CAD files were converted into high quality, solid resin parts in a matter of hours, which allowed the product development team to test a variety of patterns, exploring surface textures for a greater degree of definition and style.

The trophies were produced in three different sizes and cast in phosphor bronze by New Pro Foundries for increased durability and classic design. All the teams will be competing for the trophy named after cycling industry legend and Tour Series sponsor, Bob Chicken MBE - The Bob Chicken Trophy. The large trophy will be kept by the Tour Series in a glass case, whilst six medium trophies are given out to the overall winning team at the end of the series and 60 small trophies for the winning team of each race. With the capacity for batch production, IDC made all 67 awards in-house.

The ten round Tour Series which began in Milton Keynes on 21st May 2009 and ends on Thursday 25th June in Southend-on-Sea, is also being televised by ITV. The event is aimed at teams of cyclists rather than individuals, with five riders in each team. Exeter, Woking, Peterborough, Blackpool , Southport, Stoke-on-Trent, Colchester, Chester and Southend-on-Sea will all play host to the competition which promises to bring a carnival-like atmosphere to the heart of each town and city.

18 June 2009

3D Model for British Gas at Grand Designs Live

The British Gas stand at Grand Designs Live 2009 has a more interactive feel this year thanks to a demonstration unit crafted by IDC Models. The model showcases energy saving techniques tried and tested by the public in an eco-social experiment conducted by British Gas in 2008 called ‘Green Streets’.

“Grand Designs Live and British Gas were keen to show the best of the energy saving devices put to the test throughout 2008 by some of the homes in eight chosen UK streets. Grand Designs wanted visitors at the show to get involved and see clearly in a fun and interactive way how these techniques really worked,” explained director of IDC Models, Vince O’Horo. “Building a model that would create a life-like quality was essential. We needed to draw people in and bring it closer to reality for anyone visiting the show.”

IDC Models was asked by Rockwool Insulation to design and produce the temporary demonstration unit.

Model making specialists set to work building the cross section of a wall and roof that would illustrate three major energy saving options. The unit demanded a heavy emphasis on traditional model making skills with careful attention to detail, but also employed a blend of rapid prototyping technologies and CNC machining. Different brick patterns were also considered by the model making team, as these indicate whether a house has been built with cavity or solid walls.

The unit itself allows visitors to see inside a loft wall insulated by a medium density multi-use insulation mat called Rockwool Roll. The model also shows a cavity wall kitted out with Rockwool EnergySaver insulation to improve the thermal insulation of both new and existing masonry cavity walls.

As many pre-1930s houses do not have a cavity wall, the model makers also incorporated insulation for solid walls demonstrating the British Gas EcoRock system, which works like a cladding against the exterior wall and combines non-combustible, acoustic, thermal and energy saving insulation.

The next Grand Designs Live will be held in Birmingham in October 2009, where the model will be on display.

18 June 2009

Free iPod with your SLA parts order until the end of June

For the month of June, IDC Models is offering a free iPod shuffle for all customers placing an order for SLA parts of £300 or more. With every order worth £500 or more, customers will receive a iPod nano.

Please feel free to try the Instant SLA Quote system without any obligation. The online Instant SLA Quote provides a quick and easy-to-use way to obtain a no obligation quotation. Simply insert the dimensions of your part(s) including the part volume and quantity, fill in your contact details and submit the form, you will then receive and instant quotation via email. If you wish to proceed, simply email or fax back a purchase order and we can start the job immediately.

This offer is only on during June, and qualifying order values exclude VAT.

For further information about the service or IDC Models’ other rapid prototyping and model making services please call on 01753 547610 or visit our website www.idcmodels.com

28 May 2009

IDC Honoured for Green Designs

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Industrial Design Consultancy Ltd. (IDC) was awarded two Honorable Mentions at the Green Dot Awards for sustainable product designs that hold great benefits for consumers and manufacturers alike.

One such product design singled out for its eco-friendly credentials was the SolarStore. Costing under £100, the SolarStore is an inflatable solar collector that harnesses the sun’s natural energy to warm domestic water, heating up to three full tanks per day at temperatures close to 80C.

A product development team including designing, engineering and rapid prototyping created the green design in-house at IDC. The product saves nearly 0.2 tonnes of CO2 emissions each year. Compared to conventional solar hot water systems costing roughly £2000-3000 with payback over 10-20 years, the SolarStore has attracted much attention as it pays for itself within a six month period. There are also plans to use the product design in developing countries where electricity supplies can be erratic.

IDC’s recent development of an online Lifecycle Analysis Calculator (www.lcacalculator.com) also impressed the judges. Free for all to use, IDC’s LCA Calculator provides a quick way to assess the environmental impact of a product. By calculating its carbon footprint and energy input from cradle to grave, the LCA is a great help for manufacturers, engineers and design specialists keen to ensure sustainable product design.

Managing director, Stephen Knowles, was delighted to receive the awards, “Now more than ever is the time for people to consider the environment when it comes to product design. In our experience, green design can offer enormous benefits all round – to the environment, to the consumer for peace of mind, and to the manufacturers who can save money in the process of dramatically reducing a product’s carbon footprint.”

IDC’s product designs have been recognised by several other major awards panels recently, such as the industry respected iDEA. Its multidisciplinary product development team has been honoured for its role in creating groundbreaking medical devices such as a cost-saving disposable insulin pen for diabetes sufferers, through to more commercial products.

The Green Dot Awards focuses on highlighting and rewarding forward-thinking businesses that devise environmentally friendly products or services. They also stand as a consumer guide to excellence in environmentally sustainable practices.

17 May 2009

IDC Designs Key to Safer Prison Cells for Less

With prisoner suicide and violence a very real problem for the prison service, high-risk prisoners are housed in special cells which are safer for the occupants. Currently, these cells are custom built. But with customisation comes prohibitively high costs. IDC was tasked with finding a solution to this problem by developing a range of furniture that would effectively redesign prison cells for a safer environment without the extreme cost.

Stephen Knowles, managing director of IDC, explains, “Developing furniture for a safer cell has been a great challenge, not just in terms of design but also engineering, prototyping and from a project management point of view. IDC integrated all these activities to achieve a major redesign of HMPS cells for around half the usual costs.”

IDC developed a modular design for absolute flexibility which included a chair, single beds and bunk beds for double occupants, desk, locker and privacy curtain.

Knowles continues, “Each design had to be suicide, vandal and fire proof. We had to pick materials that would withstand impact and abrasive attack, as well as meeting strict fire, smoke and toxicity standards. Fixtures and fittings also required exceptionally careful development; we had to create brackets that would be flush to any roof – flat, arched, high or low, all depending on the prison’s architecture. High-tech adhesives were essential to conceal fixings and anchor points.”

All prototypes were made and tested in house by IDC Models www.idcmodels.com, and approved by HMPS. The safer chair and reduced risk privacy curtain are already in use across the prison estate, and the chair has been such a successful design that it is now being used in all types of cells, both high risk and standard.

2 March 2009

IDC Wins Global Awards for Life-Improving Product

IDC was delighted to receive an AsiaStar and WorldStar award for its role in designing and engineering a self-injector insulin pen that looks set to improve the lives of many diabetes sufferers.

Developed for Indian healthcare giant, Wockhardt, the insulin pen is a first in both design and functionality for the Indian market. Disposable, reusable and affordable, the pen is expected to dramatically advance diabetes treatment in India by offering a portable, quick and easy insulin dosage system for people on the move.

The insulin pen beat several hundred entrants for both awards. Judges came from seven different countries to make the decision at the AsiaStar Awards in Tokyo. The WorldStar award, organized by the independent World Packaging Organisation, was held in Cape Town. The Wockhardt Insulin Pen was compared to similar products worldwide and singled out for innovation and excellence in packaging design.

Such global recognition was particularly timely as IDC opened the doors to a new office in Hong Kong at the start of the year. The move will give the company an official base to continue a long history of working with international clients and provide added value for UK customers looking to break into world markets.

2 March 2009

UK Customers Benefit as IDC Hong Kong Opens

Industrial Design Consultancy Ltd. (IDC) has recently consolidated its international strengths by opening an office in Hong Kong.

With new clients already on its books, Chinese businesses are welcoming the company’s proven product design and innovation skills to make their own products world class. But in these testing times, UK customers designing and developing high quality products in China can also take advantage to stay one step ahead of the game by accessing valuable local support and knowledge through IDC.

IDC has a long history of working internationally with UK clients, from sourcing materials and manufacturers, to project managing the complete development of a product from design to manufacture. The Hong Kong office will provide a permanent presence in China, increasing the company’s local knowledge and access to all-important networks which aid in the process of design and manufacture.

Continue reading 12 January 2009

Outsourcing: Reducing the Risks in Difficult Times

With the Design Council’s latest findings that 54% of businesses are looking to design to ride out the recession, the importance and value of design is clear. But when projects come up that demand a broader skill set than you can access inhouse and budgets are tight, is outsourcing the solution? Or do the risks outweigh the ultimate gains?

Over the last 35 years, IDC has worked with clients when markets have been both buoyant and struggling. With experience on his side, managing director, Stephen Knowles, firmly believes that outsourcing can work for everyone as a stop-gap or project-by-project resource during difficult times. “The trick is understanding the risks involved with outsourcing, and putting in place several easy measures to ensure a swift route to success,” says Stephen.

IDC project’s director Brian Gough identifies trusting people offsite as one of the biggest fears faced by prospective outsourcers, “Getting a product just right goes a long way to boosting your sales, so entrusting part or all of its development to a new team can be a leap of faith.”

Brian emphasises two key points: to see the longer term picture and consider how a new team can add value in every way. “Outsourcing can offer a diverse pool of experts experienced in design, engineering, prototyping and more, ready to give advice and pitch in at any stage. With teams working collaboratively, as well as individually, relationships build quickly as you go along. It’s essential all round to make integrating with a company central to the process.”

With a multi-disciplinary team under one roof, customers often come to IDC with part of a project, keeping costs down and added value high on the agenda. Vincent O’Horo from IDC’s dedicated rapid prototyping service www.idcmodels.com , explains, “Prototypes are a great way to bring a product to life and check everyone’s happy with the outcome. With our SLA Viper Machine we’re able to turn around simple or highly complex models for next day delivery.”

At times like these, cost is an obvious concern. The risk of a project overrunning with subsequent spiralling costs and delays impacting on sales, is a worry.

But, says Stephen Knowles, careful planning can make outsourcing a financial and logistical blessing. “Avoiding hourly rates is sensible. Ask for a fixed price for part or all of a project. Wiser still is a results-focused payment plan which will also help keep your project within the desired timescale. Open the lines of communication and integrate to make sure everyone has the same goals. Putting clear, trackable objectives in place from the outset will prevent overrunning and set everyone’s minds at ease.”

Brian Gough isolates one other, often overlooked, outsourcing risk: the potential loss of new knowledge about markets, competitors and more, which could be reapplied in house. Brian concludes, “Collaborative working throughout the process enables the developed knowledge to be fed back to the client. Collaborative working means that there is a wealth of experience on hand. Making the most of a consultancy’s accrued experience can bring great value for money. Successful projects often develop into long term collaborative partnerships. Our longest client has been working with us for over twenty five years.”

10 January 2009

 

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