TABLE SAW TYPES

Based on the affordable price and respectable performance potential, it was decided that the Contractor saw was the best fit for the Kobalt target customer: the "Curious Improver", a heavy DIY user that is excited by the challenge of new projects.

IDEATION: HOUSING

The main goal during the development of the housing was to provide storage for all necessary accessories. The final design uses tooled-in icons to indicate where each item should be placed.

IDEATION: LOCKING LEVER

Sketching was used to quickly explore forms for the locking lever that secures the sliding table extension. The top of the lever displays usage icons, while the bottom is contoured for comfort.

FEATURES

Each accessory has a storage home, and the cord wrap hooks can accommodate an additional 25-ft extension cord. An extendable rear material support makes it easy to manage long rip cuts.

COLLAPSIBLE STAND

A simple foot pedal mechanism allows the user to quickly switch from working mode to transport mode. When folded, the saw can rest level on the ground for flooring work.

PUSH STICK STORAGE (UTILITY PATENT PENDING)

The push stick stores conveniently inside the fence for quick access. During the submission of a utility patent application, I worked closely with Lowe's legal team to provide proper documentation and clarification of the feature and its benefits.

POINT-OF-PURCHASE GRAPHICS

I also executed illustrations and graphic designs for the on-product point-of-purchase labels. These labels highlight important specs and features, and explain how to collapse the stand.

BEFORE AND AFTER

Shown is a comparison between the initial vendor proposal and the completed final design. Working collaboratively with the vendor's engineers and manufacturing experts led to an improved user experience and cohesive visual brand language.

CONCEPT DEVELOPMENT

After ten user interviews, one simulated TSA security excercise, and a focus group, we realized that storage and accessibility were key issues. We got to work concepting and prototyping with cardboard, old suitcases, and canvas.

REFINEMENT

When we had a successful prototype, the details of the concept were refined via sketching and CAD.

OVERVIEW

The SWIFT carry-on allows users to access their belongings from a number of different places, making it easy to find your passport or get to that annoying pair of shoes trapped at the bottom of the suitcase.

USER RESEARCH

To better understand the needs of heavy power tool users, I spearheaded research initiatives at multiple industrial work sites: F.R. Drake Manufacturing Company, Shearon Harris Nuclear Plant, and the Cape Fear Coal Facility.

RESEARCH FINDINGS

The research findings were analyzed and organized into a visual map that could be used to guide the development process and prioritize design decisions. Most considerations focus on Simplicity (ie quick adjustment of the wheel guard), Comfort (ie compact ergonomics and vibration reduction), and Safety (quick identification of RPM rating for appropriate accessory usage).

IDEATION: GEAR HOUSING

Rough thumbnails and more refined digital sketches were used to explore forms and details. Some important areas of focus were auxiliary handle positions, exhaust venting, spindle lock location, and the addition of stabilizer "ears" on top so that the tool can rest on its back without damaging the grinding wheel.

DEVELOPMENT

Throughout the process, 3-D CAD files served as a reference for internal components. Both sketching and 2-D vector ideation were used as refinement tools. As shown in the bottom right image. a paddle style on/off switch was added, as this was an important feature to many grinder users (because the tool won't keep running when accidentally dropped).

REFINEMENT

3-D printing was used as an important validation tool, which allowed me to evaluate the geometry for ergonomic issues that are difficult to detect by looking at a computer screen. I was in contact with our overseas manufacturing partner on a daily basis, communicating these concerns and collaborating to reach viable solutions.

SPANNER WRENCH DEVELOPMENT

Many users complain that it is easy to lose the spanner wrench, and point out that it's difficult to identify which spanner wrench is compatible with various models of grinders. As a result, I developed a universal spanner wrench that can be easily adjusted to fit any grinder. A built-in carabiner-style clip also allows users to keep it close at hand.

FEATURES

Left: Tool-free adjustable wheel guard allows users to quickly change the position of the guard by simply pushing a spring-loaded lever. Right: Kobalt's Livewire indicator is added to inform users that the tool is plugged into a power source.

FEATURES CONTINUED

(1) Auxiliary handle with anti-roll geometry, (2) Spindle lock for changing discs, (3) Top-mount auxiliary handle position for cutting, (4) Stabilization rib for resting grinder when not in use, (5) RPM rating molded into housing for easy reference, (6) Livewire indicator, (7) Lock on button, (8) On/off paddle switch, (9) Safety lockout swtich, (10) Tool-free adjustable wheel guard.

RESEARCH

A series of interviews, surveys, focus groups, and observational research led to a list of user needs. The top three needs were prioritized: (1) phones take up valuable counter space, (2) phones are often at risk of becoming contaminated by food spills, and (3) it’s difficult to see the screen.

IDEATION

We explored a wide range of ideas, many of which became focused on the concept of somehow mounting a phone to the kitchen cabinet. This would allow the screen to be viewed at eye level, save counter space, and put the phone out of the messy prep area. A secondary goal was to avoid the use of permanent mounting hardware, so as not to damage cabinets.

PROTOTYPING

We quickly moved into the physical realm to evaluate the most promising ideas. Although the early prototypes weren’t pretty, we iterated and tested them heavily, gradually improving both functionality and quality.

HOW IT WORKS

Perch can be attached to any cabinet by squeezing an aluminum plate (4), which opens a gap between the wooden support (1) and the baseplate (3). This gap fits onto the door or frame of the cabinet. When the plate is released, the tension of a large spring (2) holds the unit firmly in place. Neoprene surfaces provide extra grip to ensure that Perch stays in place.

MAKING OF PERCH (check out this video: Making Perch)

Some of the final production relied on automated equipment such as a CNC mill and a Waterjet machine. A manual bending press was used to shape the aluminum components, which were finished with a bead-blaster. We successfully manufactured 80 identical units in a span of about two weeks.

SUCCESS!

After manufacturing 80 units (and operating on little sleep), we sold all of our inventory at a sales event in less than 4 hours.

For more info on this project, visit www.PerchMIT.com.

RYOBI E-TOOLS CONCEPT DEVELOPMENT

I was involved in the early concept work for the updated line of Ryobi E-Tools, responsible for generating new ideas, visually communicating their functionality and benefits, and presenting them to cross-functional team members.

RIDIGD TILE SAW BLADE GUARD IDEATION

Using thumbnails and digital sketching, I worked with the lead designer to develop a blade guard for Ridgid's 7" Wet Tile Saw.

RYOBI HAMMER DRILL

Digital sketching and 2-D Photoshop rendering were used to refine a rotary hammer drill designed for Ryobi.

RYOBI PROMO KIT IDEATION

Each year, Ryobi releases a number of promotional power tool accessory kits. I provided early ideation sketches that explored cases, wall-mounted storage, and soft-sided bags.

RYOBI TEK4 SECURITY LOCK

A proposed addition to Ryobi's TEK4 line, this product is intended to secure items on an unattended job site. A steel cable can be looped around the object in question and threaded through the locking mechanism, which is released via a numeric pass code. I refined the design through concept sketching, and completed preliminary CAD models using SolidWorks.

RIDGID SUPERCLAMP WORKSTATION: LABEL DESIGN

Developing the labels for this Ridgid Workstation served to be a powerful exercise in graphic communication. Because tri-lingual translations are required by Ridgid's brand standards, the space was optimized by leveraging explanatory images instead of text.

MAG-SWITCH CONCEPT DEVELOPMENT

I was responsible for brainstorming potential applications of a specific magnetic switch technology, and created several usage scenarios which were presented internally.

RYOBI UTILITY KNIFE GRAPHIC IDEATION

Illustrator and Photoshop were used for 2-D rendering of graphic concepts for the blade storage area of a Ryobi utility knife.

TILE SAW RESEARCH

Interviewing and observing three user groups led to a series of key findings that were used during the design process of all three tile saw SKUs.

7" BENCHTOP SAW EARLY IDEATION

Many of the early thumbnail sketches for the benchtop saw focused on water drainage and overspray protection.

7" BENCHTOP SAW SKETCHING

Additional ideas focus on improving portability and providing a simple means for the user to read the water level inside the basin.

7" BENCHTOP SAW BLADE GUARD

Maintaining visibility to the blade and reducing the spray of water were the two primary concerns during the development of the guard.

7" BENCHTOP SAW REFINEMENT

Including cord management functionality and providing storage for the blade-replacement tools were two key concerns during the development process.

7" BENCHTOP SAW DRAINAGE DIAGRAM

This diagram was used to show how each channel in the table surface would direct water back to the main basin.

7" BENCHTOP SAW

Rendered in KeyShot.

7" BENCHTOP SAW - WATER LEVEL INDICATOR

The addition of a simple float mechanism provides the user with a simple visual about the water level inside the basin.

7" BENCHTOP SAW

In use.

SLIDING SAW IDEATION

Because many of the components of the 7" and 10" sliding saws are similar, many of the early sketches were intended to apply to both/either.

SLIDING SAW IDEATION

These sketches all relate to the locking mechanism for the fence and miter gauge of both the 7" and 10" sliding saws.

SLIDING SAW IDEATION

One of the most important components of a sliding tile saw is the rolling tray, because it is directly related to the quality of the cut.

SLIDING TILE SAW REFINEMENT

An early digital sketch of the motor housing and plunge handle assembly.

7" SLIDING SAW - WATER BASIN REFINEMENT

The most important function of the water basin is to allow water to flow down to the pump so that it can continued to be cycled through the saw. Additional considerations included filtering out sediment to protect the pump and adding a gap in the basin wall for cord management.

7" SLIDING SAW - WATER BASIN

(1) Gap in the basin wall provides convenient routing for the pump cord. (2) Fresh water intake valve allows users to attach a standard garden hose. (3) The pump resides in the deepest area of the basin and is protected by sediment filtration walls. (4) Storage for tile-marking pen.

7" SLIDING TILE SAW

Rendered in KeyShot.

7" SLIDING TILE SAW

In use.

10" SLIDING TILE SAW

(1) Angled notches help the user align tiles at 45 degrees for diagonal cutting. (2) Water overspray trays are included to collect the increased water runoff. (3) A collapsible wheeled stand allows for easy transport.

10" SLIDING TILE SAW

Because the 10" saw is mounted to a collapsible wheeled stand, it was important to ensure that all components could store easily on-board for transport mode. The water overspray trays detach and nest inside the empty water basin, which slides like a drawer.

10" SLIDING TILE SAW

In use.

RESEARCH

Interviewing servers, hostesses, and restaurant managers led to a number of valuable insights. Most notably, workers in the food service industry need to be able to prioritize their duties without distraction.

A SYSTEM OF COMPONENTS

As a result of the research, a system was developed that links all roles together, improving workflow and communication.

IDEATION

Ideation centered around wearable locations for the waitress device. A wax prototyping machine was used to test and validate form ideas.

REFINEMENT + INTERFACE EVOLUTION

Development of the user interface influenced the physical form. A series of icons were developed to help notify the server of important events, such as food being ready for delivery to a table.

ASSEMBLY

A basic clamshell design contains the internal hardware, and a proximity sensor is used for user input.

VERSATILE FUNCTIONALITY

The Cinch comes with a convenient accessory clip that can attach to a retractable belt clip, lanyard, or wristwatch strap.

APPEARANCE MODEL

3D printing and CNC milling were used to produce an appearance model, along with several coats of paint and some sanding.