SleepTracker Wearable Monitor 2008

SleepTracker Wearable Monitor 2008

Fisker-Karma-2012-4

Fisker-Karma-2012-4

Goodnature Chirp Beacon

Goodnature Chirp Beacon

Stanley Smart Measure Pro

Stanley Smart Measure Pro

Les Mills SmartBar

Les Mills SmartBar

Taska Prosthetics

Taska Prosthetics

BCS BAGgate branded for Melbourne

BCS BAGgate branded for Melbourne

Blephasteam

Blephasteam

Blade Runner 2005

Blade Runner 2005

Smartbar 2: 2018, Work done at 4ormfunction

 

Smartbar and SmartStep

Smartbar and SmartStep

Smartbar 2

Smartbar 2

Weights on bar

3.7kg Weight Plate

3.7kg Weight Plate

10kg Weight Plate

10kg Weight Plate

Smartbar

Smartbar

Gator side

Gator side

Gator top

Gator top

Exploded view Smartbar 1

Exploded view Smartbar 1

Smartbar Rack

Smartbar Rack

Smartbar testing

Smartbar testing

Concept model

Concept model

Prototype testing

Prototype testing

Concept 2.5D model

Concept 2.5D model

Rendering of final design

Rendering of final design

Basic configuration plus printers. Mounted to the BAGgate Hoop.

Melbourne Airport Branded Rendering

Melbourne Airport Branded Rendering

Production version

BCS BAGgate - Mark 2

BCS BAGgate - Mark 2

This is a rendering of the 1st production version of the BAGgate. This was designed and engineered by myself (building on the concept developed by 4ormfunction). The Hoop, Security Screen and Injector are still being produced to this design.

BAGgate Assembly Prototype Testing

BAGgate Assembly Prototype Testing

I designed and commissioned several large extrusion dies. These extrusions were suitably designed to allow mounting of all electronics for scanning and measuring the bags and could be cut to different lengths to suit individual airport requirements.

BAGgate Hoop Prototype Testing

BAGgate Hoop Prototype Testing

Testing an idea

Testing an idea

Could we orientate the Fanfold stock 90 degrees to the printer? Testing the theory. This was possible, but allowing for the large twist radius, printer depth and access for maintenance would increase the height of the kiosk.

Testing an idea

Testing an idea

If I could orient the printer and the printer stock both sideways this would solve both problems. This was a gamble so I tested the theory ergonomically and mechanically before prototyping properly.

Barcode Reader

Barcode Reader

Barcode Reader and Passport Scanner were integrated. The barcode reader was able to be mounted into the print guide eliminating a part

BCS PI Servicing

BCS PI Servicing

Serviceability was one of the key requirements of the redesign. BCS partnered with SITA who would service the units. The positioning of the printers added to this challenge but the thin / lightweight rail system I developed overcame this.

Basic configuration Kiosk

Basic configuration Kiosk

Screen Capture of Double Hoop with basic Kiosks (no printer fan fold stock or passport scanner) mounted to the BAGgate Hoop

Kiosk prototype open for servicing

Kiosk prototype open for servicing

The drop down front panel gave full access to all components

BagGate Changi Concept Proposal

BagGate Changi Concept Proposal

This retrofit solution was pitched and was awarded for Changi Airport - Singapore.

Changi Aiport Singapore Installed

Changi Aiport Singapore Installed

Proposal for flexible checkin

Proposal for flexible checkin

This system was proposed for a new airport terminal. This image shows the system in self checkin mode on the left and aided checkin on the right.

Proposal for flexible checkin

Proposal for flexible checkin

This image shows the system in self checkin mode

BCS BagGate: 2011-14, Work done at 4ormfunction

 

The brief was to research and design an equipment solution for use in the Les Mills group fitness class BODYPUMP:

“It must be innovative to reflect our programme and Les Mills brand. We want unique intellectual property and it must be cool”

The result was the globally patented and multi award winning Les Mills SMARTBARTM. A unique fast plate changeover barbell specifically designed for the needs of group fitness classes - along with weight plates that are ergonomic and versatile in their use. I was involved in the development of the whole range of Les Mills SmartTech equipment and took a leading role in the development of the 2nd Generation Smartbar.

Four years, four generations to streamline the airport check-in experience: BAGgate for BCS.

 

I was then responsible for designing a production version, (2nd gen) designed for batch production and customisation, with a Single and Double configuration.  I was the sole designer and managed the design, prototyping and production of the first five systems (approximately $1/2 million build). 

 

The 3rd generation was the design of a modular kiosk to suit various airport requirements and regulations including the incorporation of two large bag tag printers.  The result was radical and highly successful. The kiosk was so slim it was possible to wall mount or hang from the Hoop, or be integrated into a wall. This flexibility and serviceable design made it suitable for retro-fitting to existing airports and helped BCS convert many large opportunities.

 

Lastly I lead a team pitching to an offshore airport in partnership with BCS to develop a new system that was adaptable over the transition to automated baggage drop off. We presented a system with pivoting screens allowing an attendant to aid check-in when needed.

Stanley Smart Measure Pro: 2015, Work done for ikeGPS at 4ormfunction

Concept sketch

Concept sketch

This sketch formed the foundation for the engineering development. I then modelled this up in solidworks and created all the main components and did a lot of the mechanical detailing myself

New product design, design direction. 

 

Following up on the ikeGPS Spike where I led the concept refinement, mechanical design and production, ikeGPS attracted the attention of Stanley who saw the massive potential of the technolgy. Shoot and measure; More than a laser measurement device. You can measure nearly anything in the photo. Cool technology and a great and challenging project to lead, and it was a great success.

I led the project from concept through to production handover, doing the industrial design, CAD surfacing, mechanical detailing of the external components and working closely with the engineers developing the clamp mechanism and optics.

SleepTracker watch: 2008, Work done at ByMethod

Pro Elite version

Pro Elite version

This product was designed in 2007 - 2008 and is still in production.

Watch Comparison - Before and After

Watch Comparison - Before and After

Early Opportunity Scoping

Early Opportunity Scoping

CAD model - strap attachment detail

CAD model - strap attachment detail

CAD model - mechanical details

CAD model - mechanical details

Concept Ideation

Concept Ideation

Concept Development

Concept Development

Concept Development

Concept Development

Exploring opportunity to add perceived value through materials and finishes

Concept Refinement

Concept Refinement

Male and Female Concepts

Male and Female Concepts

Marketing departments in Korea helped guide the male concept towards a casual sport aesthetic.

Functional Prototype

Functional Prototype

Mens version, Production Sample

Mens version, Production Sample

Production watches

Production watches

These versions were released later and marketed as male and female versions.

SleepTracker engaged ByMethod at a strategic level, which I lead, to revitalise the company.

 

SleepTracker is a sleep monitor. Sleeptracker wanted to maximise the investment they had made in the electronic hardware of a wearable sleep monitor (that wasn't selling because it was too big) and "re-design" it to make it something that could be worn every day. The challenge was making it appear smaller without changing the internal volume. The brief was to reduce the visual volume and appeal to a sporty, professional demographic.

 

My role was the lead designer, working closely with the client and marketing team to establish a design language for a range of products to be built on. Once an aesthetic was established I developed the professional sport concept as the first to market. I provided production ready 3D CAD files as well as providing colour, materials and finish specifications.

 

Designed in 2007 -2008 this design is still in production. 

© 2019 by Carl Menary

Les Mills SmartBar

3.7kg Weight Plate