Expertise. Willy Yonkers. 4 Case Studies

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1 Willy Yonkers - 4 years as lead industrial designer at ThinkGeek.com - 5 years as staff industrial designer at Tres Design Group - Freelance industrial design with clients across the East coast - Design & fabrication of exhibits at the National Building Museum - Design contractor for the Human Computer Interaction Institute - Design contractor for the National Robotics Engineering Consortium - BFA in industrial design from Carnegie Mellon University Expertise - Modeling complex organic forms in SolidWorks - Sketching, model making & prototype fabrication - Aesthetic & mechanism ideation & research - Pre-engineering plastic injection molded parts - Working around electronics & RF constraints - Communication across discipline & language barriers - Hand held control layout & ergonomics - Licensed product development 4 Case Studies

2 Update an in-cab remote for controlling a contractor grade snow plow and salt spreader. - durable and water resistant - easy to navigate - short learning curve - visible at night - usable while wearing gloves - come with wired and wireless versions - be comfortable to use while driving - be hard mountable to the dashboard - user programmable macro functions Existing solution - inelegant - fragile - expensive - lacking features User observation - understanding how it is used - extreme conditions - involves a complex sequence of moves - making it easy to use & explain Exploring mounting locations - easily reachable - visible without distraction - consider fasteners or brackets Snoway ProControl - Research

3 Illustration Pistol grip - Trigger salt spreader - Multi-speed trigger & lock - AUX shoulder button - Macro screen menu - Hand strap Sketching Finger board Modeling - Separated functions - Straps to operator s leg - Removable palm rest - Dash mountable - Flex-cable mounting - Compact & rugged - Closest to existing - Long joystick Inspiration Pendant remote Drawing Snoway ProControl - Ideation

4 Concept refinement - rounded - friendly - colored buttons - sleek - faceted rubber - wrap around lens - geometric - rugged - wrapped in rubber - industrial feel - long joystick SolidWorks 3d CAD Control layout exploration SLA Rapid prototype Snoway ProControl - Refinement

5 Component selection Final product - multi-color LED back lighting - 2 line 20 character LCD - rechargeable li-ion battery - analog click joystick - mother and daughter PCBs - custom RF board Prototype stuffing & testing Final BOM & assembly sequence - smaller than the previous version - controls are thoughtfully arranged - all buttons are accessible by thumb - supports wired and wireless versions - simple 2 part molds for all parts - much more versatile and powerful Snoway ProControl - Implementation

6 Create a game controller for ios - non-app speci c - work across devices & Android - increase accuracy & precision in gaming - reference retro arcade styling icade jr for iphone & Android - Designed by ThinkGeek - Produced by ION April fools mockup - Invented days after the announcement of the ipad ION production icade - Interpereted by ION to reduce shipping size 8-bitty handheld controller - Designed & produced by ThinkGeek - Patented keyboard control system icade jr - Product line

7 Hacked PS2 Controller ergonomics model Initial CAD Re ned CAD - Removed the light-up marquee - Added speaker details - Created landscape mode shelf Foam core full scale mockup Assembly sequence & BOM icade jr - Development

8 First generation Segway HT Develop a wireless key fob which would act as the vehicle instrument panel and remote starter. - replace existing 3 key system - connect wirelessly instead of via contact socket - display more precise battery feedback - display fault conditions and error codes - water & impact resistant casing - small and possibly wearable fob - develop a mounting system for control stem - stay true to the personality of the original - create a stylish jewel object of envy Second generation i2 Segway InfoKey - Research

9 Inspiration Form development Previous solution Final form & interface Mounting location questions - visibility on control stem - distance from safe driving view - outdoor sun glare - positioning on a bent extrusion - protection during a crash - ease of removal Drawing communicating - lines of sight - relationship between parts - positioning on the stem - possible impact points Quick-mount assembly instructions Segway InfoKey- Ideation

10 Beginner Button Information Display Button Display Area Materials selection based on RF interference - metal keys - case screws - battery - piezo speaker Power/Standby Button Warning Icon Segway PT Battery Gauge InfoKey Controller Buttons Information Display (time, distance, speed, etc.) Security Button Wrench Icon (Service) InfoKey Controller Low Battery Icon AC Power Icon Face Icons Security Icon Rider Detect Error Icons InfoKey Controller Link Signal Icon Beginner Icon Accommodating micro-circuitry scale tolerances InfoKey Controller Display - culturally independent - readability considerations - making meaningful icons - versatile numeral area Segway InfoKey - Implementation & Interface

11 Create a new line of electric staplers which stay true to the styling of their existing Optima - work with ergonomics & usability researchers to understand the user and stapler use - work with in house engineers to accommodate existing internal mechanisms - one hand held, rechargeable grip version - three larger desktop models - larger models incorporate staple removers & storage - maintain styling cues across the line - optimize clinch area viability - incorporated page counter & depth stop Existing electric Swingline staplers Swingline Optima manual stapler - our inspirational target Swingline Optima Staplers - Introduction

12 We partnered with BLUEPRINT usability to uncover - who our user group is - how they use existing staplers - what they expect from staplers - any confusion over labels or mechanisms - color & form preferences - how to encourage users to staple correctly with grip areas, curves & labels We partnered with Metaphase ergonomics research to show - how the hand interacts with a stapler - what postures are used when stapling - what challenges there are when using a stapler - what grip schemes are most powerful vs most accurate - what forms fit the palm best when using a stapler How the hand interacts with a stapler Grip schemes & postures when stapling Usability testing of existing optima stapler & competitors User group is predominantly women Swingline Optima Staplers - Research

13 Snarl - large desktop form - broad/ blunt cap - segmented body shell - protruding lower jaw - differentiated lip/ gum area - grip version retains cap, lower jaw, and segment lines - derived from SolidWorks experimenting Saddletooth - small hand held form - aluminum shell connects two inner plastic bodies - standing vegetable form - pro version has inner bodies stretched apart and cutaway element is moved to the rear - derived from hand sketch Hammer - large desktop form - tower over clinch area implies a high power piston motion - closest to previous Optima stapler - grip version is truncated - derived from Solidworks experimenting Swingline Optima Staplers - Ideation

14 Swingline Optima Staplers - Grip Illustration

15 Swingline Optima Staplers - Pro Illustration

16 Grip mechanicals Pro mechanicals Refining the chosen concepts to better fit the internal mechanism and reflect changes suggested by the client - 3/4 front views of the existing mechanicals - full scale 3 view drawings of grip and first pro versions - due to the products complexity, we were only delivering external styling while only making sure the mechanism would fit inside with a fair margin or error Swingline Optima Staplers - Refinement

17 Full scale, solid body rapid prototypes Group SolidWorks rendering - showing scale & common elements Swingline Optima Staplers - Implementation

18 Photos of production staplers Low force manual staplers European market plier staplers Ultimate grip stapler Swingline Optima Staplers - Production & Beyond