SL Knee Brace

Transcription

SL Knee Brace

Example 2
Identifying the problem
To identify the need for a specific product, I met with my client in order to understand my client’s
requirements and ideas of goods he desired. After conversing with my client, I created 3 possible
projects: a knee brace; a helmet; or a back brace. After further discussion with my client a choice
was made that I was to construct a knee brace. Below are three brainstorms and discussions on each
concept and later the email correspondence with the client.
Design technology teacher support material
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Example 2
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Summary of 1st Meeting with the client:
I met with the client and discussed a number of possible pieces that fitted exactly what he wanted. I
proposed my three project ideas: Knee Brace; a Helmet; Gloves. He warmed to the knee brace
immediately, as he recognized the danger with motor biking and skiing. Later I investigate his
motorbike leathers and bikes to develop a colour scheme for the brace.
Summary of email from client:
“Thank you for your email about the design and construction of the knee brace. I have answered the
questions to the best of my ability:
1. I plan on wearing it as much as possible when I participate in extreme sports such as motor
biking or skiing
2. Like I stated above, I will use them mostly when motor bike riding and skiing.
3. I would like my knee brace to be comfortable yet protective. This may mean spending more
on knee brace than others, but I am prepared to pay the costs involved if the knee brace is
of the high standard I so desire.”
Design brief
“The significant increase of participation of young and middle-aged people in dangerous adventure
sports is the most rapidly increasing cause of lower limb injury, in particular, fractures of the bone
and dislocations of the knee. It has overtaken conventional traditional motor vehicle accident
trauma as the primary cause for admission to accident and emergency centers in our community.
Passive protection for occupants of motor vehicles has very significantly reduced the rate of serious
lower limb injuries. Protection for participants in high-energy adventure sports is often minimal or
inadequate. The provision of modestly priced, effective knee braces has the potential to bring about
a significant drop in the incidence of knee injuries, similar to the beneficial effect that mandatory use
of helmets has had on head injuries on cyclists and skateboarders.”
The knowledge acquired and ingenuity developed during the design process for adventure sports
protective bracing may also prove useful to the design and manufacture of remedial braces for the
injured and elderly populations.
The intention is to provide an affordable, comfortable, effective knee brace, which addresses the
dangers and specific needs of the target market.
Major constraints:
The brace needs to be affordable/not expensive, but be just as safe. The complexity of the brace also
needs to be reduced, as the brace needs to be able to be adjusted with gloves. Also the brace cannot
be too complex as it will discourage some people who think it is too complex.
Research and Design question
Can a brace be designed which meets the above criteria? Several important issues have been
identified with regard t the performance and design criteria, and these will be discussed below.
The main areas of interest to be addressed:
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Ease of Use: The person using the knee brace must be able to figure out how to use it with
little, if any, instruction.
Diversity of Application: Since there is such a large range of potential users, the Knee Brace
need to be very user friendly and easy to use for all, and adaptable to the needs of different
sporting groups, and suitable for clientele of any age, shape or size.
Materials: Shell, skeleton and fastenings
Budget: this varies on the target market involved but our focus will be on suitable materials
with an affordable cost
Recyclability: the product will be manufactured from a variety of materials. The
environmental cost of sourcing and handling these materials will need to be considered at
the time of our materials selection.
Aesthetics: the colour, texture and feel of the product is recognised as being of great
importance to consumer appeal
Versatility: The Knee Brace will be more popular and successful if it suits a broad spectrum
of applications, adventure sports and remedial
Ergonomics: size, physical comfort and psychological comfort (how safe and secure it feels)
will be important to its success
Safety: issues of safety for the young, elderly and physically challenged will be considered
and potential hazards “designed out” where possible.
Focus problem:
A product’s aesthetics is an important factor and probably almost as important as its primary
function in terms of sales success. Good design can create a product well suited to its task but also
attractive to the eye and comfortable to wear. This has a great opportunity in all markets because if
there is any way the If our Knee Brace is found to be more effective than its competitors but remain
affordably priced it could become very successful across a very broad market demographic. It should
appeal to the extreme sports range because they are performance oriented and need a robust
product, but also attract the older remedial brace clientele who may be more price sensitive and
need a brace that’s easy to manage.
There is also a very large range of age as well with people from around 12+ using them worldwide on
a daily basis. This means that a very large percentile range of leg size a process also needs to be
considered when designing a product for this field.
The design goal:
The design goal is to design a Knee Brace that is more versatile in its ability to protect the user in a
variety of situations the Brace must provide support and effective protection, it must be easy to
apply and comfortable to wear. Ergonomics are important and design attention will be paid to the
ease of using fastenings and making adjustments. It can’t be too visually complex, its operation and
fitting needs to be intuitive.
Target Market
For arthritis or the elderly, weight will be a consideration. They may also be concerned about how
bulky the brace is. A lightweight close fitting brace that they van wear under their regular clothes will
be more appealing than a more bulky appliance that they have to wear over their clothes. Apart
from protecting them injury a effective but comfortable, lightweight brace would encourage them to
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Example 2
be more active. The elderly are often in a fixed low or no income situation. As purchasers they are
inclined to be more price sensitive than the younger population. This needs to be held in mind when
selecting materials and manufacturing costs. We may need to have two styles of braces, one being
more robust and complex but with a price premium. The other being made of less expensive
materials and perhaps having less complexity but available at a more economical price.
There is a large range of age as well with people from around 10+ using them worldwide. Because of
this, a large percentile range of leg and knee size would be important, and need to be considered
when designing a product for this field.
Another thing to consider is the assembly of the product. If the item is too complex to manufacture
with ease, a large amount of time would be wasted on the assembly line and cause problems. Also if
it was too complex, machines could not be used to assemble the product so prices would increase
here because of humans being needed for assembly.
Finally the intuitiveness of the product should be considered. The elderly are usually a rather
technophobic age market so if a product is too complicated or they cannot figure out how to use the
product just by looking at the product, they are likely not to use it.
The criteria:
The criteria in which a good design solution can be generated would be:
The performance: This is very important in a product such as a Knee Brace. The more functional it is
the more practical it is and with the elderly and adventure sports target market, a Knee Brace that is
easy to use, but effective would be favoured heavily.
How intuitive the product is: If a product is too complex to use, some people they will most likely
return it for a simpler product.
Ergonomics: The balance of the Knee Brace/the shape/how light or heavy the product is/is it both
useable for the elderly and younger ages/fits the correct dimension of leg size etc. (5th-95th
percentile range)/shape/size.
Choice of Materials: This factor has a lot of impacts on others in the design process. The budget is
impacted by the choice of materials for example Carbon Fiber could be used for production yet it is
rather expensive. It also affects weight, shape and feel. The strength of material needs to be
considered i.e. choice of quality, anti-corrosive, durable, stain resistance, density and abrasion.
Safety Factors: with a knee brace, safety is paramount to assess and keep in mind. Weight is
important, as it is possible that the product can come apart, or splinter in use, and it is important to
ensure that the product is impact resistant and rotationally resistant so it does not injure the user.
Warnings on both the product and packaging instructing on the correct use should be included. This
should ensure the company is not sued for not adequately describing all safety features and
providing sufficient instructions on how to use the product.
Reliability: The product needs to e able to be used for a long time. It also needs to be able to be
cleaned quite easily. If the product appears safe the consumer is more likely to use the product more
often.
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Aesthetics: probably the biggest criteria for a product being selected at a place of sale is appearance.
This is also important when considering both male and female consumers.
Construction: This is important in considering cost of both time and production e.g. if it was injection
moulded the product must be able to be assembled quickly, as stated above, if it is not it could
create problems in the assembly line and make the manufacturing process longer.
Cost: the knee brace must not be expensive because in this sector there are a large amount of
options at varying process, and many price sensitive groups. However, it cannot be made of cheap
breakable materials so you must balance booth the cost of production and the competitive nature to
create a product in this field.
Selecting Variables of Specifications
I intend to design and create a Knee Brace that fits the criteria specified above is effectively protects
the wearer from injury in a variety of situations. Knee Brace performance criteria that need
consideration include:
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Resistance to staining and moisture
Smooth and impervious surfaces requiring less time and effort for cleaning which would
increase customer satisfaction
Replaceable lining and fastenings to improve the serviceable life of the product.
The Knee Brace needs to be intuitive in design and the functional ergonomics will be important as
the product is to be targeted to suit both males and females within the 5th to the 95th percentile
range of leg sizes. It must adapt to significant variations in leg length and girth. The shape must fit to
the natural curve of the leg so it will be provided in both left and right versions and available for
purchase as a single or pair. The padding and straps are to be designed to be quickly and easily even
by a user wearing gloves. The Knee Brace must be light and manageable such that all users males
and females, young and old feel confident putting on the brace and using it for their chosen activity.
The choice of materials will also contribute to the users feeling of comfort and security in the brace.
Affordability will be a key factor when considering this design. Quality and cost are generally
expected to go hand in hand. Clever design, material selection and manufacturing processes can
help minimize costs whilst a desirable appearance, good performance and durability justify a higher
sales price, therefore maximizing profitability.
For example Carbon Fiber is a strong material, resistant to water damage and corrosives but is
expensive. An alternate material may be less expensive, but would its performance be adequate to
satisfy the requirements? With the inevitability of impact and collision, safety is paramount and the
target market are discretionary spenders and recognized as being prepared to spend more money
for a better performing product.
Market
Cost (retail) – cost is important. If the price is set too low it will be difficult to make a profit and there
is a danger that the market may perceive that it is of a lesser quality. If the price is too high it will
reduce the numbers able to afford it.
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Appeal – if it doesn’t look safe, people won’t buy it. If its not visually attractive or looks too
complex, people won’t buy it
Synergies or partnerships may be available with manufactures of other related makers of protection
gear or specialized apparel. This could increase sales by broadening market exposure. Potential
buyers might enter a store looking for another items and then see the brace and consider purchasing
it also. This means our product exposure in effect benefits from the other items marketing.
Our initial biggest problem will be the lack of awareness of our product by the consumer. There are
two aspects to this. The first is that a high percentage of the target market doesn’t realize how
important it is that they wear a brace. The second is awareness of our brand versus that of our
competitors amongst those who are looking to buy a brace. We would hoped to address both these
aspects through advertising and expert appraisal in industry publications and websites.
Mediums – advertisements, magazines, and television, and branding on flyers, signs and stickers
Legitimization – appraisal and testemonials from elite sports identities and medical experts
Enquiries to be made
Motorbike riders, skiers Snowboarders (novice to experts)
Retailers
Governing bodies (experts, medical, legislative, material)
Likely manufacturing centers (locations, processes)
Testing (local testing facilities, product trialling, production trials regarding time and costings.
Price/costs
Cost of materials – this will depend on which material I chose for various parts of the brace. The
materials chosen must suit the different aspects of the brace.
Cost or development (specifically Research and development – if this brace were to go into full
scalke production, the costs of research and development would be large because of all the testing
for the best posssibhle brace.
Promotion – If the brace were to enter full scale production, advertising would be required to
increase consumer awareness of the product.
Handling (packaging) – the knee brace will be packaged, to protect the knee brace.
Collaboration
Roadbike companies
Wakeboarding companies
Off-road bike companies
Skateboarding
Skiing companies (water and snow skiing)
Pretty much any extreme sports companies
Collaborating with another company that supplies gear could be immensely beneficial, because then
the costs of manufacture would be less of a problem and it would also increase sales of the brace
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Example 2
drastically, because the knee brace is seen as part of a ‘set’ of clothing, like motor biking outfits or
skiing outfits.
Sales/selling the product
Advertising campaigns – highlight the differences in cost/pain/pleasure between getting a knee
brace or sustaining an injury. This is important as it will encourage more potential consumers to buy
the product, increase consumer awareness of the brace.
In the event of injury
A leg injury can be horrific with its impact on daily life. You may be unable to work, and you certainly
will not be able to participate in fun activities. Most likely, you will sustain a lot of pain, and there is a
chance it could be permanent injury. However, this predicament can be prevented with a knee brace
– this point is very important to emphasize to increase the appeal to potential consumers.
Highlighting the relative cost of this protection in context of frequency of injury, and cost of injury
would be beneficial for consumer awareness.
Design features
Many knee braces are designed to address a specific aspect of danger or potential injury and may
therefore not be well suited to alternate sports of applications. For example most skiing and
snowboarding braces have focussed on impact resistance but overlooked the risks of rotation or
hyperextension of the knee. The users think they will be safe from harm, when in fact their brace is
only protecting them from the most obvious mode of injury.
The brace I design must have better functionality than existing knee braces. If it is better, the more
people will buy it.
Competitive on price – if the price is too high or too low, it will reduce the number of braces sold.
Attractive (ergonomics, aesthetics cost) – the brace must be attractive to increase favourability.
However, attractiveness cannot be substituted for safety. Ideally, the brace will be safe, and
attractive to potential consumers.
Easy to adjust – the problem with knee braces today is that most are hard to adjust. Some require
knowledge tha a everyday person would not have, and so they could not fit it properly, and may, as
a result, increase the chance of injury. Having the brace come with a simple set of instructions for
DIY adjustment would greatly boost attractiveness. In the same way, since the brace is for extreme
sports, the adjustable parts must be quick and easy to adjust.
High level of durability (2-3 years of use) – If the product can last for a long time, people will be more
inclined to buy it, as it is more of a long term investment for safety.
Accommodations of other actors (fashion, style, new developments intechnology) – if new
technology should arrive, it should be easy to accommodate the new technology into the already
incorporated brace.
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Example 2
Materials
Body armour (Kevlar, carbon fibre, thermo malleable plastics) – the armour is important for the
resistance to impact. Must be made out of a sturdy material, but cannot be too stiff, otherwise it will
be uncomfortable
Hinges (I can use pre-existing hinges that are cost-efficient, versatile, durable, safe and simple) – the
purpose of hinges is to allow adjustment for the brace, for weight gain/loss, or letting someone else
borrow it.
SANTOPREME
Neoprene
Struts (adjustable, durable and hard, impact resistance. Materials that will not shatter into splinters
if broken
Padding – durable breathable, fits contours of body, clean, washable, sun durable – the padding is
crucial in the brace.
It is important to have good padding as no one will buy an uncomfortable brace. Also the padding
cannot rub after prolonged usage as this will aggravate the consumers, and limit potential fiture
sales.
Armour/protection
Body armour must be able to withstand side impact and front impact, to protect the thigh, knee and
shin.
Attachments
Soft padding (foam)
Velcro for tabs and straps – Velcro is important so the brace and straps are easy to adjust with
gloves on.
Replaceable foam or straps when too dirty or damaged. If the foam is not replacable, the brace will
smell and get dirty, and stop people from using the brace.
Must be non-combustible material, so riders don’t have to worry about their pants catching on fire
because of the exhaust pipes on motorbikes.
No loose straps can be present, to prevent catching on twigs or bike parts (this can be avoided by
the addition of Velcro straps) – having loose straps is dangerous, as the straps could catch on
anything, form the bike, to another car in extreme cases. This can end up with extremely bad
injuries.
Design features
Impact protection (knee, shin, thigh) – important for bikers and skiers. This will protect them from
fall damage, or hitting something with their knee.
Rotation protection (to protect against unnecessary rotation and hyperextension – the main
problem with braces today. The braces are too focussed on impact protection to account for
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Example 2
anything else. Many injuries are actually not from the impact, but from excessive rotation or
hyperextension. The brace I will design will have rotation resistance as one of its top priorities.
Struts
Materials (no fracture, just deform in the event of strong impact) – deformation is better than
fracture as it lessens the risk of skin penetration or laceration and the injury may be more easily
repaired.
Variable length (inside/outside) (thigh/shin) (tall/small) – The brace has to be able to fit the majority
of people (roughly 5th to 95th percentile), to accommodate for all users. This will increase the size of
the available market niche.
The struts should attach to any boot with a collar fitting, by means of screwing it in or snap fitting it
on, as then boots and knee braces will be seen more as a single unit more than 2 separate parts.
In the event of a collaboration, the knee brace can be specially designed to suit the companies
products, this will promote and increase sales for both companies.
Hinges
Must be variable, to accommodate all sizes of people.
It must have a simple ‘lock’ on multiple stages of flexion for the brace. This will make it easier for
people to use the knee brace, as it reduces the complexity. If it has fixed positions, say 0, 30, 60 and
100 degrees, with labels like walking and sitting, people will know when to adjust their knee brace,
and it would be easy and simple to adjust the brace for all activities (running, walking, riding, skiing,
sitting, laying down)
May be colour coded for easier detection of the separate angles or lock positions – as stated above,
will help with simplicity and increase the attractiveness.
Must be cleanable – if its is dirty, no one is going to wear it.
Must control rotation – the hinges will have to be comfortable to be against a person’s leg, but must
also protect the level of rotation allowed in a leg.
It must not rust – if it rusts, it will be dangerous, and could create injury
Must be able to withstand shock impact – the hinges must be hard, so they still work after a strong
impact or fall.
Manufacture
Core costs:
Research and Development
Materials
Machinery/Mechanisation – if the brace was full time produced
Location of manufacture – imports/exports of the brace, with the different currencies.
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Unit numbers of production – depends on how well the brace is selling, and the level of demand for
the brace.
Pricing based on other existing product – the prices of other braces will help me to set the price of
my brace at a competitive price.
Diversity (sizes, Styles Colours) – to please all consumers, whether they are a young child or middle
aged man.
Left and right braces, total dimensions – the left and right leg are different, therefore I will only
make one brace, but suggest ways in which it could be incorporated onto the other leg.
Interchangeable parts, or universal parts for all units – would again increase attractiveness, if the
parts are interchangeable, and you can purchase them anywhere around the world, more people
will be inclined to buy my brace because of the convenience of and cost efficiency of only having to
buy one piece of the brace, instead of a whole new one. However, this will be considered strongly,
as the implication of this idea will harm future sales in the long run, even though it may increase
sales of separate parts in the short run.
What’s wrong with the current knee braces?
Don’t address rotation – Excessive rotation is one of the most common causes of knee injury and
fracture but this is not well understood by consumers
Don’t control hyperextension – As above, not well known by any of the potential consumers
Not universally adaptable to all boots – this is a very big niche. Currently, none of the available
braces attach to boots. Implicating this idea will increase sales, as it will portray the brace as
universal, and convenient. Because it latches on to other boots, it will be looked upon as more safe,
and more people will turn to this knee brace rather than any other.
Not user friendly
Difficult to comprehend – the knee braces available today are not easy to understand, without
professional instruction. One of my aims is to create a simple knee brace, so that people can put the
knee brace on and proceed to use it without a ‘professional’ in that field having to instruct them.
Non transferrable person to person – with the addition of Velcro straps and instructions, it may be
possible for my brace to be interchangeable between people. However, this could again harm future
and long run sales. If this idea is used, it would have to be firstly considered with caution
Most need tools to adjust ‘in the field’, or when in use – I will design my brace so that it would not
require tools like a screwdriver to adjust and change the knee brace when in use.
No simple release to extension block – most braces need to be adjusted before different usage. For
example, walking after a motorbike ride or after going skiing. The knee brace will be designed so that
it is easy t adjust the degree rotation allowance of the knee brace, so that people can quickly change
tasks without having to worry about using a screwdriver to adjust the brace.
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Example 2
Research
For my research, I am going to use a variety of sources. These sources are:
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Samples of knee braces
Testing of Materials
Secondary
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Internet sites containing the range of knee braces
Videos and internet sites explaining the knee braces
People size programmes
Books
I will need to test these materials in Aesthetics, Stain resistance, Durability, and Strength. I will
perform a number of tests that will tests these various attributes.
Aesthetics: I will need to analyse each product closely and compare physical and visual factors.
These factors will include smoothness, visual aesthetics, colour and shape.
Durability: I will need to put these materials through a number of tests to access their durability. The
first test will include rotating the Knee Braces, to see how far each one rotates. The second test I will
perform for durability includes leaving samples of the materials in water and salt water for a set
amount of time to test how resistant to staining/rust each different material is. The final test will
test the hardness of the product. The Knee braces must be resistant to impact. SO therefore I will
take all the materials and hit the materials with a variety of objects, drop them and generally test
the impact resistance. Also I will test to see if it is possible to misuse this product and if so, how
resistant is the knee brace to misuse.
Through these tests I will gather data and record results and be able to compare all the materials
and ultimately be able to decide what material will be best for the manufacture of the knee brace.
Primary research
Client interviews
Performance tests
Visiting Hospitals, firms
Process undertaken
By interviewing the
client I can understand
his specific wants and
needs
By doing performance
tests I can gain an
insight into what
specific materials will
work best under the
circumstances that my
client has specified
By visiting hospitals
and disturbing outlets,
I can take photos and
analyze different
braces to get ideas for
the brace I am to
Benefits from research
I will understand the
wants and needs of my
client
Priority of research
1
I will gain an
understanding of the
appropriate materials
that will suit product
2
Will be able to have a
greater range of ideas
for the product
3
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Example 2
Interviewing industry
participants
Interviewing users
design
By interviewing
industry participants, I
will be gaining an
insight into what is
expected and how to
improve the average
knee brace
By interviewing users, I
can photograph and
analyze different types
of braces and show
them to my client to
aid his decision in
which materials and
style he wishes to
choose for the knee
brace.
Secondary research
Percentile range
research
Process undertaken
Researching percentile
range data
Information books
Reading and analyzing
information books
about the market
Referring to design
magazines
Reading and analyzing
magazines
Internet
Website searching
I will greater
understand the overall
expectations and
standards of the
market
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I will understand the
characteristics of the
materials and can help
my client make a
choice on which
material they want to
use
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Benefits from research
By researching the
percentile range that I
will use for my
product. I will gain an
insight into what sizes I
need to make specific
sections of the knee
brace, to make sure
that the brace is not
ergonomically
uncomfortable
By going through
information books, I
will be able to
understand what types
of methods would be
best for me to use on
the product. For
example, joining
methods or finishing
methods
By reading and
analyzing magazines, I
will gain an insight into
what trends are
popular now and
consider possible
concepts that I may
use for the knee brace
To find different online
Priority of research
1
2
3
4
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Example 2
ideas and information
about knee braces
Interview with client (primary)
Considering that the product can be used as a
preventative or as assistance post injury, which
type should we produce?
When I observed you wearing the knee brace,
you seemed reluctant to take it off during
breaks. Why was this?
I know you have not chosen the design, but do
you have a faint idea of the colour and shape
you want?
Is there any specific material that you would
prefer for the inside padding?
Any important additional notes regarding design
that I haven’t already addressed yet?
I belive that it would be better to produce a
‘preventative’ knee brace, so that it is applicable
to more people, and could potentially become a
standard item for extreme sports.
Well, the knee brace I use now is a hassle to put
on and take off, so I’d rather have it on all day
and experience a little discomfort than waste
time taking it off and putting it on again.
I personally don’t mind about the colour
although I can see that it would be important for
some people. I want the knee brace to be as slim
as possible so it doesn’t inhibit my movement
when riding or skiing.
I haven’t thought of a specific material, but I
would want the material to be comfortable, but
be able to be cleaned easily so I don’t have to
replace it all the time and spend more money on
foam.
The knee brace needs to protect from rotational
injuries, rather than impact. If someone crashes,
they could break/injure their knee even with a
knee brace. However, if the knee brace protects
from rotation, we can prevent most of the
injuries that require a knee brace in the first
place.
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Example 2
POTENTIAL MATERIALS
• Body
• Carbon fibre
• Polyacetate
STRAPS
• Velcro-straps
PADDING
• Foam-padding
• Rubber-sole (potentially)
OTHER THINGS TO CONSIDER
• Lifespans? – 2 years generally
• What percentile will they amke it for? – 5th to 95th
• The leading companies and types of Knee Braces?
POPULAR FIRMS/COMPANIES
• Zimmer_(medical braces)
• Fox- motorcycle bracing
• Don joy – medical braces (rehab)
• Ossur – Orthopaedics
An appropriate test to perform was a density test. This
test was to test how resistant the samples of material
were to objects being dropped on them, compared to
carbon fiber. To do this, a pipe was held above the
material, and a 2.5cm steel ball b#earing was dropped
from the top, into the pipe, hitting the material on the
other end. This was a controlled test because the pipe
was the same height each time and the pipe was narrow
enough that the ball bearing would hit relatively same
area each time, maximising accuracy.
After the ball bearing was dropped,
the depth and diameter of the
crater/dent left was measured, using
a vernier calliper.
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Example 2
The results were as follows:
Material
Diameter (cm)
Depth (cm)
Bamboo type 1
0.27
0.01
Carbon Fiber
0.20
0.005
Flexi
0.59
0.02
Fiberglass
0.25
0.01
Luan
0.43
0.02
Glass
Shattered
0.8
The Carbon fiber was least dented, and had the smallest radius after the impact. Because of this it
would be the most appropriate material.
Carbon Fiber
Carbon Fibre is a material consisting of thin. Strong crystalline filaments of carbon, used as a
strengthening material.
Carbon fiber has many useful properties that would make it ideal for a knee brace. The properties of
carbon fiber include: high stiffness; high tensile strength; low eight; high chemical resistance; high
temperature tolerance and low thermal expansion.
Carbon fibers are usually combined with other materials to form a composite. When combined with
a plastic resin and wound or moulded it forms carbon fiber reinforced plastic (often referred to as
carbon fiber) which has a very high strength to weight ration, and is extremely rigid although
somewhat brittle. However, carbon fibers are also composed with other materials, such as with
graphite to form carbon-carbon composites, which have a very high heat tolerance.
Opportunity cost of flexibility vs hardness/rigidity
Polyacetate
Polyacetate is a material used primarily for making clothes. It is a polymer of vinyl acetate and it is
often forced to undergo hydrolysis to remove some of acetates after polymerisation [a chemical
process that combines several monomers to form a polymer or polymeric compound]. The more
acetate that is removed, the more water-soluble the polymer becomes. If it is soluble in water, it
means that the material will not dissolve in water.
When the polymer is used for making clothes, the acetate is left on the polymer, so the clothes do
not dissolve. The polymer absorbs water easily, and is flexible, which is why it is used to make
clothes.
Velcro
Hook-and-loop fasteners consist of two components: typically, two strips of material, which are
attached to the opposing surfaces to join and fasten. The first material has tiny hooks; the second
has even smaller loops, the idea being that the hooks get caught on the loops and hold the two parts
of material together. This is only temporary, however, as the two materials can be pulled apart easily
by someone. When separated, by pulling or peeling the two surfaces apart, the Velcro hooks are
pulled from the loops, creating a ‘ripping’ sound.
Velcro has several problems: it tends to acquire increasing amounts of hair, dust and fur in its hooks
after a few months of regular use. After extended use, the loops can easily become elongated or
broken. Velcro often becomes attached to clothing, especially loosely woven things like sweaters.
Additionally, the clothing may be damaged if a consumer attempts to remove the Velcro, even if the
actual peeling of the Velcro is done slowly. It also absorbs moisture and perspiration when worn
next to the skin, which means it will smell if not washed.
16
Example 2
Because it is easy to use Velcro is used in many situations where a temporary bong is required. It is
especially popular in clothing where it replaces buttons or zippers, or, in this case, to strap the knee
brace to someone’s leg. (easily manipulated by hands)
Foams
With foams, there are two types. These are:
Open-cell structured foams contain pores that are connected to each other and form an
interconnected network that is relatively soft. Open=cell foams expand, and fill any type of container
it is administered to, like water. If the foam is filled with air, the foam can be used as a good
insulator, but if the foam fills with water, the foam will be heavier and not insulate as well. Foam
rubber is a type of open-cell foam.
Closed-cell foams have pores that are not connected to other pores. The closed-cell foams normally
can be compressed tighter and more easily, due to the structure of the foam. However, closed-cell
foams are also denser, require more material, and as a consequence are more expensive to produce.
When choosing between the types of foams, cost will be a key factor of the final choice, as well as
density, as it must not be too heavy for sustained use. The closed-cell structure foams have higher
dimensional stability and higher strength compared to open-cell structured composite [attaching
two thin, but stiff, skins to a lightweight but thick core] materials (don’t absorb sweat, dirt, smelly
water)
Rubber
The use of rubber is full of variety, ranging from household to industrial products. The largest
consumers of rubber are tubes and tyres. These raw materials that are used can be a whole variety
of things, from petroleum, coal, oil, natural gas, and acetylene. Most of them are copolymers, i.e.
polymers consisting of more than one monomer. If the composition is changed, it is possible to
achieve properties that are specifically desired for unusual or special appliocations. Ethylenepropylene rubbers (RPDM) have high resistance to weathering and subnlight. This resistance makes
it very useful and it is used for automobile parts, hose, electrical insulation and footwear.
COMMON INJURIES
There are a number of common injuries to the leg caused through extreme sports. These are:
• ACL injuries (occur when the anterior cruciate ligament is overstretched by the knee bending
backwards or twisting awkwardly). These are classed in 2 ways:
o Non-Contact ACL injuries
o Contact ACL injuries
•
MCL tears (where the medial collateral ligament on the inner side of the knee gets
overstretched and damaged)
•
Knee Sprain (when one of the knee ligaments overstretches which tears some of the fibres in
the knee). There are three grades:
o Grade 1 – a few fibres (less than 10%) are damaged/torn
o Grade 2 – more fibres are torn but the ligament is still intact
o Grade 3 – the ligament is ruptured – completely torn.
17
Example 2
Advantages
Can prevent
collision-based
injuries with the
kneepad, can
tighten up with
laces at the back.
Disadvantages
Primarily protective
of impact, overlooks
hyperextension and
rotational aspects of
the knee. Looks
complicated to put
on. No instructions
on how to properly
tie up back.
Ergonomics
Open framework makes
it breathable during
use. No professional
help needed to fit
brace.
Laces are copious and
long, they get tangled.
Laces are
uncomfortable when
used under clothes.
Storing
Back can be
compressed
quite easily,
so easy to
store in
narrow
spaces.
Safety
Shell made from
reinforced, nylon
injected plastic.
Strong, yet light.
Knee pad in middle
and armour on the
thigh and shin
protect against
impact. Can turn
leg to the sides
quite easily.
Aesthetics
Red and black.
I believe this is
suitable, as it is
applicable to
both genders.
Materials
Nylon injected
plastic shell,
foam insides.
Laces and nylon
back.
The
Donjoy
“Defiance
III”
(£620)
Very easy to put
on, and not
complicated at
all. Lack of plating
at the front
means that the
leg is able to
breathe much
easier, and is not
uncomfortable
during use. Slim
and sleek, easy to
wear under
clothes.
No plating on the
front. Lack of plating
means that debris
and a serious
collision could still
injure your leg. Very
light and feels unsafe
in comparison with
others.
One piece, so easy to
store and to put on.
Pressure is spread
evenly on the leg. No
liner on the inside of
brace, so slightly
uncomfortable at times.
Adjusting and using it is
simple and easy. Clips
could pinch skin if
strapped carelessly.
Convenient
to store
because of it
being one
piece,
however,
difficult to
store as it is
big and
plastic
Framework
effectively prevents
hyperextension.
However, because
of the lack of
plating, any strong
impact could easily
damage the knee.
At first looks
very high tech
and light.
Looks
uncomplicated
. Red and black
are
aesthetically
pleasing. Clips
look easy to
adjust, and
strong.
Shell is carbon
fiber, creating a
strong frame.
Hinge appears to
be made out of
stainless steel
and a carbon
fiber casing.
Straps from
Carbon Fiber,
allowing easy
adjustment and
allowing user to
easily to strap
and unstrap
themselves.
Donjoy
Reaction
knee
Can treat a range
of injuries.
Doesn’t require
Primarily protective
of pain in the knee
and doesn’t protect
The open frame and
mesh makes it
breathable and
As is entirely
elastic, easy
to fold and
Not suitable for
extreme sports as
it wouldn’t protect
Sleek and
black. Gender
netral. The
Elastomeric web
– rubber-like
qualities. Velcro
EVS Axis
Sport
Adult
Knee
Brace
($224.10)
18
Example 2
brace
($85)
help to fit.
ProCare
KneeRAN
GER –
Lite ($99)
Has a lock
position which
can protect from
hyperextension.
Has a splint which
keeps the knee
straight and
hinges circle
around to protect
from impact.
McDavid
427
Thermal
deluxe
hinged
knee
support
($195)
Open knee which
allows it to
breathe. Hinge
system allows
locking the brace
to different
angles. Surface
area is relatively
small reducing
against impact,
hyperextension and
rotational aspects.
Because of the
elasticity, it does not
support the knee
particularly
effectively. Lacks
protection as it has
no stiffness.
Wouldn’t be good
under impact.
Locking system
requires adjusting to
do a different
activity. Splint
prevents intention
rotation, so could
limit movement.
Needs to be specially
fitted. Time
consuming to put on.
Difficult to remove
and replace.
Locking system
requires adjusting to
do a different
activity. Hing could
restrict intentional
rotation.
comfortable.
store
the knee very well/
colour range is
limited and
could be
expanded.
would wear and
require replacing.
The cuffs allow air
movement around leg.
However, stress points
at the four points where
the cuffs are. Could hurt
after prolonged use and
rub against the leg.
Doesn’t fold,
so needs to
be stored at
full size.
Looks safe and
strong. Looks
easy to wear
and
comfortable.
Black with
white lines
indicating
adjustable
parts.
Splints are
carbon fiber,
therefore strong
but lightweight.
Steel on hinge
resists rust. Cuffs
made from
carbon fiber and
foam padding
with velcro
straps.
Stress is evenly
distributed. Restricts
airflow, meaning after
prolonged use, it could
get hot and sweaty
casing discomfort. Easy
to remove.
Flattens, so
easy to
store.
The splint and lock
mechanism
provides support
and keeps the
wearers leg
straight in use.
Padded straps and
plastic structure
protects against
impact and could
prevent a range of
injuries.
Lock ensures safety
of the knee. It
prevents
hyperextension
and keeps the knee
straight. No
padding or impact
resistant material.
Suitable for
Looks
comfortable
and easy to
adjust. Black in
colour with no
padding. Could
be worn under
clothes.
Hing/splint is
made of carbon
fiber, therefore
strong support.
Hing is also made
from corrosion
resistant Steel.
Additional layer
of neoprene
19
Example 2
chance of
discomfort
through chafing.
rehabilitation
rather than
extreme sports.
RS8 PRO
KNEE
BRACE
($481)
Dual padding
over knee
protecting from
impact. Suitable
for extreme
supports. Large,
but lightweight.
Doesn’t require
fitting and can be
adjusted to fit
most users.
No holes or areas for
skin to breathe,
could get hot and
sweaty. Splint is
thinner, risk of
rotational injury.
Difficult to wear
under clothes.
One piece spreading
pressure evenly.
Comfort-liners prevent
irritation. Liner is
detachable for cleaning,
however it could unclip
in use causing
discomfort. Straps clip
in place, so easily
adjustable. Clips could
pinch the skin.
One bulky
piece makes
it difficult to
store.
Dual pads on knee
protect from
frontal impact.
Thick carbon fiber
shell is strong. Side
struts help to
restrain rotation.
Clips ensure brace
sits well on the
knee.
Looks high
tech and safe.
Red and white
improve
appearance.
Looks easy to
adjust and
strong.
Extreme
Sports
Hinged
Knee
Brace
One strong pad
over knee
protecting from
impact. Suitable
for extreme
sporst. Brace is
made from
Carbon fiber and
is lightweight.
Brace does not
need to be fitted.
Breathable.
Little protection on
thigh or shin.
One piece, so easy to
put on. Hinge supports
leg and prevent motion
over 165 degrees, so
little chance of
hyperextension.
Sharkskin neoprene
ensures comfort and
increases grip. Clips
make the brace easy to
adjust.
Can be
compressed
and folded –
easy to
store.
Pad on knee
protects from
impact. Lack of
protection on shin
or thigh.
Looks very
protective and
comfortable.
Logo is
recognizable.
Large knee pad
looks safe.
Clips look
strong and
used with
Sharkskin
neoprene will
make the
brace secure.
prevents hing #e
from rubbing or
pinching the skin.
Velcro strap
allows easy
adjustment.
Shell made from
Carbon Fiber,
therefore strong
frame. Hinge is
stainless steel.
Sye-Suede is
made from Suede
cloth increasing
comfort. Straps
are carbon fiber
allowing easy
adjustment.
Knee pad from
Carbon fiber, so
strong. Hinge is
made from
aircraft grade
aluminium, so
won’t rust. Lining
is made from
sharkskin
neoprene
preventing
slippage. Straps
are carbon fiber
and allow easy
adjustment.
20
Example 2
DATA PROCESSING ANALYSIS
In the research component of my project I have collected and analysed data to aid my client and
myself in choosing different aspects for the final product.
First I chose a series of primary research tasks, the first task was to interview my client regarding the
knee brace. The interview with D was very helpful as it made me aware of the specifications and
qualities of the knee brace that was important to him. Also I gained an insight in to which sports D
would be doing with the knee brace, so I could make it more specific to his needs.
After discussing basic questions with my client, he stated he was interested in rotational protection,
because of this I proceeded to examine established knee braces in order to see the amount of
rotational protection they provided. This would help D to make his decision on what style of knee
brace he wanted. J stated that he wanted a knee brace that was primarily focussed on protecting
rotation injury.
Once the style of knee brace was chosen, I undertook a series of performance tests to understand
the limitations of the products tested. My first test consisted of testing the impact strength and
rigidity of the carbon fiber. After the testing, my client decided that the most rigid and strong
material would be appropriate for the shell of the knee brace. Additionally, I measured my clients
knee so that I could specifically make the knee brace to his specifications. I also conducted Percentile
Range research from the 5th to 95th percentile range for Australian male leg size so I could
understand the basic dimensions needed for the knee brace to be ergonomically acceptable for my
client (target market)
In conclusion to my research component of this project, Carbon fiber production methods were
investigated. I chose 5 different knee braces to look into further detail as I thought they would be
most appropriate style and design when creating the final product.
21
Example 2
Design 1
22
Example 2
Design 2
23
Example 2
Design 3
24
Example 2
Design 4
25
Example 2
Design 5
26
Example 2
DEVELOPMENT
Design option 1:
This design is likely to be strong yet rigid. It is simple, with the straps in the back and the adjustable
hinge on the side of the knee. The brace would be used with protective leathers, as there is no
external padding on the brace, but only rather an exoskeleton. One disadvantage of this specific
design is that there is no foam and because of this, it could be uncomfortable to wear. Storing it
would be slightly difficult, as it is a whole brace, and does not compact at all.
The materials used in this product would consist of a carbon fiber splint and carbon fiber cuffs. The
hinge would be made out of plastic.
Design option 2:
This design is likely to be strong, yet springy and elastic. The product is simple having only two straps
on the back with the cuffs. This brace would be used with protective leathers as once again there is
no external armour on the brace,. This brace does not have foam because it would fit tightly onto
the leg to provide strong support. The half splint on the thigh and calf prevent the leg from rotating
too much. Storing it would be slightly difficult, as it is a whole brace, however, it would compress
slightly because of the springiness.
The materials used in this product would consist of a carbon fiber splint and carbon fiber cuffs. The
hinge would be made out of plastic.
Design option 3:
The design is likely to be strong with protection and worn on the outside of the leg. The product is
simple, having plate like armour on the front of the thigh and calf, and simple clips on the back. This
brace would be used with unprotected motorcycle leathers as there is external armour on the brace,
making it unsuitable to wear on the inside of motorbike pants. This brace would have foam on the
inside, as the armour is not shaped to the contours of the leg, and is flat. The hinge would be linked
on the splint, to allow the different positions of locking the brace. The cut outs in the thigh and calf
splint would allow the leg to breathe.
The materials used in this product would consist of a carbon fiber or fibreglass armour plate and
neoprene foam. The hinge would be made out of plastic.
Design option 4:
The design is likely to be springy and light, and worn on the inside of pants. The product is simple,
twirling around the leg, finishing at the two cuffs on the thigh and calf. This brace would be used
with protective motorcycle leathers, as there is no external armour on the brace, making it suitable
to wear on the inside of motorcycle pants, and not applicable to wear on the outside. This brace
would not have foam on the inside, as the brace is shaped to the contours of the leg. The hinge
would be linked on to the spirals, to allow the different positions of locking the brace,. The copious
spaces the thigh and calf parts would allow the leg to breathe. The materials used in this product
would consist of carbon fiber or fibreglass.
27
Example 2
Design option 5:
The design is likely to be strong and restrictive of movement, and worn on the inside of pants. The
product is simple, being a massive sleeve, having the hinges and protective parts hidden under the
foam on both sides. This brace could be used with either protected motorcycle leathers, or nonprotective. Because of the outside and inside foam, the race would conform to the contours of the
leg. The problem is that the foam will not allow the leg to breathe very much.
The materials used in this product would consist of a carbon fiber or fibreglass. And neoprene foam.
28
Example 2
Clients comments on the design options:
Design
idea
1
Reliability/Ease of use
Safety factors
Aesthetically pleasing
Materials
Storage
the product looks simple
to use, to me, it looks easy
to take off and put on.
From looking at the
design, the product looks
aesthetically pleasing.
However, once again it
looks lacking in
protection from impact
I am happy with
the carbon fiber
suggested
Storage wise, it seems like it would
be an awkward thing to store if
there wasn’t a long rectangular
space.
2
The product looks simple
to apply. To me, like the
previous brace, it looks
easy to take off and put
on.
The lack of padding is
concerning. Although I
specifically wanted a brace
that protected against
hyperextension and rotation,
collision impact should be
considered strongly.
The springiness really would
support the leg, giving it
much better protection
against hyperextension
I am happy with
the carbon fiber
suggested
Storage wise, it seems like it could
be an ordeal to store, however,
with the compression of the brace,
it would be slightly easier to store.
3
The product looks simple
to use, as the clips are very
ordinary and common. To
me, it looks very reliable,
with armour plating.
The plate armour would
protect against impact and
the straps in conjunction
with the splint would stop
the leg from rotating
unnecessarily.
From looking at the
very light and sleek. It
also looks like it can
compress under pressure,
which is what it is meant
to do.
From looking at the
very sleek and strong. It
also looks stylish and high
tech
I am happy
carbon fiber or
fibreglass, as I
know they are
both sturdy
4
The product looks
somewhat complicated to
use, as the brace spirals
around your leg. To me, it
looks somewhat flimsy, but
the springiness that it
offers would provide good
support.
The product looks very
The lack of armour would not
protect against impact, so it
would have to be worn with
protective motorcycle pants.
From looking at the
very intricate and
complicated. However, it
does resemble a sleeve,
so that aspect is good, as
it shows how it is meant
to be put on.
From looking at the
Carbon fiber
would probably
be more suitable,
as it is more
springy.
Storage wise, it seems like it could
be a problem to store. The flatness
will definitely come in handy to
store in slim and rectangular
spaces, however, it could become a
problem if the space isn’t square
like.
Storage wise, it could be a
problem. The spiral nature of the
brace means it cannot be flattened
or compressed sideways. It would
require a large space to store
effectively.
5
The internal passing would
The sleeve would
Storage wise, it would be easy to
29
Example 2
easy to use, as it clearly is a protect against impact,
slide on brace
however the protection
would be increased in
protective pants. The hinges
in the foam would prevent
the unnecessary movement
in the leg
very simple and easy to
use.
be made out of
neoprene. And
the skeleton of
the brace and the
padding would be
made out of
carbon fiber or
fibreglass
compress with the foam, so it
would be more convenient to store
that the other designs.
30
Example 2
31
Example 2
32
Example 2
Exploded view
33
Example 2
Procedure
Equipment list
Roles of fibreglass (6)
Tubigrip (60cm)
Foam (100x12x15)
Ruler
Tape
Lead pencil
Plan of production
The black boxes shaded in below show the estimated time of production.
Procedure
Dates
March
April
May
26th – 30th 16th – 20th 23rd – 27th 30th – 4th
Acquiring foam
Cutting foam and
assembling
Putting the mound
together
Cutting
Sanding
Fiber-glassing the
mould
Cutting the fibreglass
Filing the fibreglass
Attaching the foam
Attaching the straps
Constructing additional
inserts
7th – 11th
14th – 18th
Choosing materials
Through the use of performance tests, primary research and secondary research, I was able to gain further
insight about what I was to be incorporated and not to be incorporated in my final product. When working
out what type of material i was going to incorporate in my clients product, I interviewed D (user trial) and
asked him whether he was interested in a more impact resistant brace or a more hyperextension protection
focussed brace. After D told me he was interested in the protection of hyperextension and rotation, I
focused my designs around that idea.
In the initial performance test I conducted regarding density of the materials, I concluded that carbon fiber
would be the most appropriate material to use. However, we first both agreed that it would be beneficial if
a working prototype was created first. In addition, I used trigonometry and mathematics to formulate the
most appropriate angles for the brace. It was especially challenging to accommodate for the level of
compression the fibreglass would put on the foam.
34
Example 2
Choosing manufacturing techniques
Cutting
Mitre saw and band
Using the two different sawing methods, the mitre saw and
saw
the band saw allowed me to understand the difference in ease
and quality. The Mitre saw was safe and practical in
comparison to the band saw, although the product moved
around a lot (if not clamped) and additionally the teeth in the
saw blade were quite large so it left large scratches if not done
correctly. In comparison, the band saw is much more
dangerous, although the product seemed to be more stable
and it cut more accurately.
Sanding
Disk sander and
Sanding was one of the longer processes that I underwent in
Different grit sand
producing the product because I sanded it with numerous
paper (80, 120, 240, different grit papers. In sanding, the grit paper that I used
400, 800 grit)
varied from 80 grit all the way up to 800 grit. The sand paper I
used to sand off the fibreglass was definitely more efficient
filing by hand.
Gluing
PVA adhesive (glue)
When gluing the product, I had to make sure that I was gluing
directly on to the foam. However, glue proved too messy and
difficult to use, and so I resorted to using tape instead. Thus to
overcome this problem I masking taped the area that I was
going to glue so the mold would be easier to make. In gluing I
tried to us PVA glue that is used for hobbies like model making
and paper machete, although it has a very strong bond once
hardened.
Measuring Standard 30cm ruler, Measuring was a very easy task and was done with three
combination square
different ruler types. The standard ruler was used to measure
and set square
the foam so that I could get a good length. The protractor was
used to measure the angles in which I cut the foam pieces.
Strategies for testing
In testing my product back against the initial specification, I underwent a number of different tests in both
the form of objective testing and subjective testing. Briefly explained below:
Objective:
• Testing the measurements of each of my clients legs and designing the brace accordingly
• User trials
• Evaluation of the product against the specifications (PDS)
Subjective
• Reviewing the possible colour scheme of the knee brace in contrast to the motorbike leathers it is
used in conjunction with.
• Modifications that could be made in the future
Subjective testing
When I asked the client for his opinion on the product, he stated:
"The products turned out very close how I imagined it to be. In my opinion, the product fits both form and
functions well. Quite obviously its function is to restrict the rotational movement of the leg, which is does
well and in regards to form, the product is very aesthetically pleasing as it contrasts with the black colour of
my motorbike leathers.
35
Example 2
In regards to storage, the product has been mediocre. However that was to be expected, with a brace of
this type. Quiet obviously it fits my leg, although the idea of having the adjustable straps has been a great
help when I find that I am wearing another set of clothing underneath my leathers.
Through you filing and sanding the product, I understand that it is a lot easier to put on, and a lot less
painful. The sanding has given the brace a softer feel. The product also conforms with many other
motorbike gear I have, like my chest plate. As seen below in three pictures of the brace on my leg.
“If I could change anything about the product, I would ask that the brace was a bit easier to put on. I find it
a bit of a stretch to put on with the small cut out in the back. Perhaps if the opening was bigger I wouldn't
have that struggle” DJ, my client
Below are the strengths and weaknesses stated by my Client after a month of use:
Strengths
•
•
•
•
•
Ease of mobility, the product can be
compressed and extended easily
The colour of the fibreglass contrasts with my
motorbike leathers
The brace is strong and sturdy
The Brace fits the client
Has the potential for adjustments, and also a
potential for interchange between persons
Weaknesses
•
•
•
The opening at the back is a little small
The product is hard to fit under my
motorbike leathers
The product is hard to clean in the way that
the foam is glued on
Conclusion
My design goal stated that I was "to design and produce a durable, aesthetically pleasing, ergonomically
sound Knee Brace that serves its purpose to protect the user. The top priority is to make the product
prevent rotation in the leg of the user"
From the evaluation against specification section further in my evaluation which out- lines the
initial specifications, an understanding can be made about how well the product fits the initial
specifications and the design goal/brief.
In regards to whether the product is considered to be long lasting/reliable, it is difficult for me to
answer considering that my client has only had the product in his possession for use for
approximately two weeks. Although in regards to the reliability/quality of the product, that would
36
Example 2
heavily influence the long lasting factor of the product, D (my client) stated that he feels protected
from impact, and that he cannot rotate his leg to a large degree, even if he tries (which is good).
Evaluation against specification
After reviewing my research and understanding the clients testing, I will now evaluate how well the product
abides by my initial specifications
Initial specifications
Performance of product.
•
•
•
The product must be able to protect the user. To do this, I will have to measure his leg and create the
width of the brace accordingly
The Knee brace needs to be strong so it will not break or chip easily if dropped. To do this I will need a
quality Fiberglass that can withstand being dropped
The knee brace should be relatively scratch resistant
Reliability
•
•
The Brace should be sturdy in its design
The Brace should be able to be used numerous times without wearing away of the Fiberglass or foam
Ease of use (including ergonomics)
•
•
The brace should be relatively straightforward in use
It should not be straining on the user when putting on and taking off the brace
Safety factors
•
•
•
•
•
•
The brace should have smooth edges and corners so that there is minimal chances that the product
could cut or pinch the consumer
The brace has to be impact resistant
The brace has to prohibit leg rotation
The brace cannot be heavy so that it doesn't hurt if it is dropped on someone. Aesthetically pleasing
In order for the Brace to be appealing to the customer, not only should it perform its purpose, it
should also be good looking. Although aesthetics are not the most important factor to a knee brace,
it is still a contributing factor.
Additionally, the concept for aesthetics should be realistic and achievable to produce. o The
aesthetics must conform with the environmental surroundings around it
Materials
•
The materials the brace has been made out of must be strong, yet relatively light.
Construction of the product (including time of manufacture)
•
•
I must be efficient in the time used when constructing the product, making sure the product is
produced before the deadline
I must use the facilities in my workshop as much as possible and try not to outsource to much as it
will only slow the production process.
Cost of product needs to be competitive (more appealing to customer)
•
D has stated that he will not have a problem with the cost as long as he deems the product of good
enough quality.
37
Example 2
Storage
•
I need to be conscious of the size of the product as it may become difficult to store to fix this, I must
not create excess space that won’t be used.
Hygiene
•
•
•
Try not to make the foam interchangeable
The Fiberglass must be applied evenly so it is relatively resistant to moisture and dirt
If straps are used, they should be interchangeable so that they don't get dirty.
Performance of product
My initial specification states that:
•
•
•
The product must be able to protect the users knee when participating in extreme sports.
The knee brace needs to be strong so I will not break or chip easily if dropped. To do this I will need a
quality Fiberglass that can withstand being dropped
The brace should be relatively scratch resistant
After completing the product whether I have met these specifications has become clear. In relation
to my client’s Brace protecting his knee, I can say that this was successfully completed and this is
further backed up by the feedback I received from D. In addition to the Brace protecting his knee,
the implementation of the adjustable tightness in the back allows for differing clothing and differing
users.
If I was to re-do the joinery methods, of the mould, I probably would have gone with a glue, as the
mold would give less when being fiber glassed, and retain its shape more.
Reliability
•
•
The brace should be sturdy in its design
The brace should be able to be used numerous times without wearing away of the foam or
fiberglass
After completing the product, whether I have met these specifications has become clear. As stated
previously in my performance evaluation, the product was very sturdy/stable in its design as it was
somewhat rectangular. The shape further increases its sturdiness, as the product cannot bend in on
itself when in use.
Ease of use (including ergonomics)
•
•
The brace should be relatively straightforward in use
It should not be straining on the user when putting on and taking off the brace
The product is very ergonomically sound as it is a very straightforward product with no out- standing
complicated concepts that need to be understood before properly functioning the product. In
addition, there are only straps to tighten and loosen. The only possible complication I can think of in
the product is that it is too small or too big, however that’s why multiple molds were created, to give
the option of having a smaller or bigger brace Had I focused more on the ease of use aspect, then I
would have filed inside the brace as well, to provide the smoothest experience.
38
Example 2
I also made sure that my molds and product was in the 5th to 95th percentile range for average
Australian males aged 15-64 in regards to leg size as otherwise some users would not be able to
function the knee brace properly
Safety factors
Initial specifications include:
•
•
The brace should have smooth edges and corners so that there is minimal chances that the product
could harm the consumer
The material should be smoothened or being relatively planed so that there is minimal chance for the
consumer to be affected by splinters or sharp surfaces
When producing the product, some of the safety factors became obsolete such as the need for filing
the inside of the brace, as it would be covered by foam instead. The quality of finish the sides of the
brace was obtained by using 420 grit sand paper so that, not only will the product look aesthetically
pleasing but also the product will be safer for users as it reduces the chance of contracting a splinter
or getting cut. With the high sanding, I made sure I rounded the edges, only slightly, on the corners
so that if someone fell onto it, or was wearing this in an accident they would not injure themselves
badly (i.e. Piercing the skin)
Aesthetically pleasing
•
•
•
In order for the knee brace to be appealing to the customer, not only should it perform its purpose,
it should also be good looking. Although aesthetics are not the most important factor to a knee
brace, it is still a contributing factor.
Additionally, the concept for aesthetics should be realistic and achievable to produce.
The aesthetics must conform with the environmental surroundings around it
Through choosing an aesthetically pleasing frame and shape indicates that I was conscious of aesthetics in
the product. Fiberglass is highly regarded for strength, but also is aesthetic compared to other
substances. Although white stands out a lot, it still conforms with its environmental surroundings as it
not seen when in use. The texture of the product is smooth due to frequent sanding with high grit paper
(420p).
When constructing the project, I made sure that function came before form as I believe that the most
important aspect for the product is that it serves its purpose (in this case to protect the client) rather
than be aesthetically pleasing and hinder on how well the product works.
Improvements to the product
In addition to the improvement possible in the production process many aspects of the final product could
be improved in specifics, safety and storage. The product is quite dangerous in the sense that there are lots
of sharp sides all around the product. The problem with these sharp points is that it creates the issue of
people accidently scratching or cutting themselves. The impact that this would have would be great, as it
would further reduce my target market. In order to solve this problem, I should have rounded off the edges
to make the product more safe and friendly. The problem with the being square like is that it will be harder
to wear under clothes. In order to fix this problem, I could have cut the angles wider so that the fiberglass
didn't pull back the foam so much. In addition I would've added a kneepad to the center, for extra
protection from head on collisions.
39
Example 2
Modified design specification: when suggesting improvements for the weaknesses of the product that I devised, I would say one major issue is the sharpness of the product.
I would make sure that the injection press produced smooth edges to increase comfort.
40

SL Knee Brace

Transcription

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