SBD LDM on MotoX - 1st Gen - small

SBD LDM on MotoX - 1st Gen - small

Taska_003

Taska_003

Les Mills Smartbar 1

Les Mills Smartbar 1

Spike for ikeGPS

Spike for ikeGPS

Les Mills Smartbar

Les Mills Smartbar

I have been lucky enough to design award winning and innovative products that have helped many companies grow and succeed internationally. Here are a few examples.

 

Click the above images for more information.

Sketching and Concept Origination

 

SBD LDM on MotoX - 1st Gen - small

SBD LDM on MotoX - 1st Gen - small

Laser measurement device on phone

Design for manufacture concept

Design for manufacture concept

Concept sketch

Concept sketch

Artex Blade Runner. Styling Concept Work done at Fearsomengine 2005

Concept bulb

Concept bulb

Male and Female Watch Concepts

Male and Female Watch Concepts

Form study sketch

Form study sketch

Sleep Tracker Concept Sketch Work done at ByMethod, 2008

Concept sketch

Concept sketch

Architectural Communications. Cover Panel Removal Concept Work done at ByMethod, 2008

Ideation

Ideation

Client: CDHB Work done at 4ormfunction, 2014

Form study sketch

Form study sketch

Omnex Display Mount Elevation Work done at Form3, 2007

Notebook Lock

Notebook Lock

Tightening Mechanism Concept (allows the lock to work with all brands of notebooks) - Patented Work done at ByMethod, 2008

Label Holder - Customisation Concept

Label Holder - Customisation Concept

Formstudy - sketching in 3 dimensions Work done at Form3, 2007

Illustration

Illustration

Nomadic Drums Folding Down Illustration Work done at Massey University 2002

Ideation and conceptual development is the short stage of the project where there is infinite possibility. The research and workshops have brought to light opportunities, established problems or unmet needs and the designer can build a set of ideas that will form the basis of the product concepts. At this stage I find working in loose freehand sketch format is the most efficient.

Design Development

 

Fisker Battery

Fisker Battery

Fisker Karmer Battery pack design. Work done at Form3 2008. I worked on the mechanical detailing of the battery housings and cooling systems. It was a collaborative process involving several teams working closely together.

Quick and Dirty Ergonomic Study

Quick and Dirty Ergonomic Study

Industrial Remote - Form Sketching in 3D Work done at ByMethod 2008

Industrial remote ergonomic study Work done at ByMethod 2008

Rack mounted equipment - creating a brand identity Work done at Form3 2007

Label holder Work done at Form3 2007

Vitamode Body Measurement System

Vitamode Body Measurement System

Work done at Boxclever 2004

Vitamode exploded view

Vitamode exploded view

Work done at Boxclever 2004

Omnex Battery pack

Omnex Battery pack

Work done at Form3 2007

Gunlach Trowel - Modular System

Gunlach Trowel - Modular System

Work done at ByMethod 2008

Notebook Lock

Notebook Lock

Auto engage and retract lock. Clutch - unlocked Work done at ByMethod 2008

Payment Terminal Prototype

Payment Terminal Prototype

Work done at Boxclever 2004

Embodying ideas into refined concepts that can be communicated to the wider team for feedback. Ideas meet mechanical solutions. 

Model Making and Prototyping

 

Scale foam models

Scale foam models

Work done at Diplomat, 2006

Omnex Industrial Controller Model

Omnex Industrial Controller Model

For ergonomic evaluation in the field. Work done at Form3, 2007

Omnex Industrial Controller Model

Omnex Industrial Controller Model

Ergonomic testing. Work done at Form3, 2007

Omnex Industrial Controller Model

Omnex Industrial Controller Model

Display mount form study - plasticine Work done at Form3, 2007

Hospital Head-panel prototype

Hospital Head-panel prototype

Work done at 4ormfunction, 2014

Vitamode - cardboard model

Vitamode - cardboard model

Work done at Box Clever, 2004

SleepShifter - form study

SleepShifter - form study

Work done at ByMethod, 2008

SleepShifter - Prototype

SleepShifter - Prototype

SLA or Stereolithography rapid prototype. This is the go-to mechinical assembly verification prototype process. Work done at ByMethod, 2008

Fast Track full scale model

Fast Track full scale model

Work done at Form3, 2006

Painted watch model

Painted watch model

Work done at ByMethod, 2008

Prototyping happens throughout the design process. Some products are more suited to begin design and development with physical models, especially where ergonomic requirements are paramount or the material dictates the design possibilities. In this case I like to sketch in 3D, sometimes with plasticine, sometimes whatever is at hand: paper, wire, duct tape. But as the design firms up, more precise methods and more representative materials  are needed. And somethimes it's necessary to create models that are suitable for product photography or design verification testing.

 

I have experience making all types of prototypes; from foam to five axis machining, from micro electronics to architectural installations.

Design for Manufacture

 

Les Mills Weightplates

Les Mills Weightplates

I designed the weight plates and detailed for production, coming up with new innovative ways to manufacture weights to a higher level of quality than has been ever seen in the exercise industry.

Stanley Smart Measure Pro

Stanley Smart Measure Pro

As the industrial desinger and design director on this project, I designed and CAD modelled all exterior components and worked closely with the manufacturer through testing to achieve signoff.

Omnex 2nd generation Controller

Omnex 2nd generation Controller

Concept CAD model

Exploded view - Omnex Display

Exploded view - Omnex Display

I designed and detailed the Display module, providing production file set. This was an IP67 rated product and passed the tests without any need for tuning. Work done at Form3, 2007

battery pack

battery pack

Design detailing

Omnex Controller with display

Omnex Controller with display

Sheet metal design

Sheet metal design

Sheet metal enclosure for payment terminal. Designed to visa PED standard with anti-tamper protection. Work done at Box Clever, for Trintec, 2004

KSI Tissue Slicer - Assembly Drawing

KSI Tissue Slicer - Assembly Drawing

Work done at 4ormfunction 2014

Kerr Scientific Tissue Slicer

Kerr Scientific Tissue Slicer

This was one of a range of accessories developed by myself in a short time to meet a tradeshow dealine. This was designed, machined and assembled within 2 months and the prototype was production quality. Work done at 4ormfunction 2014

BCS BAGgate

BCS BAGgate

A range of processes were used to prototype and manufacture the BAGgate. These needed to be lowsetup cost and offer the ability to customise later. So extrusion, fabrication, sheetmetal and PU casting were chosen. Work done at 4ormfunction 2012

BCS BAGgate kiosk concept overview

BCS BAGgate kiosk concept overview

Work done at 4ormfunction 2013

BAGgate kiosk prototype - open

BAGgate kiosk prototype - open

Design for maintenance. This kiosk opens with a single key, the front panel drops down giving full access to all hardware. Work done at 4ormfunction 2013

ikeGPS Spike

ikeGPS Spike

Assembly process testing testing in the factory. Work done at 4ormfunction 2014

Spike Assembly Testing

Spike Assembly Testing

Lightpipe and button insertion testing Work done at 4ormfunction 2014

My knowledge of production process has formed through working closely with many manufacturers throughout the design and build process. These relationships have given me confidence and competence in many areas of manufacture but I always enjoy learning about and trying new processes or applying a known process to a new material to push manufacturers' capabilities. 

CAD Modelling and Rendering

 

Smartbar Rendering

Smartbar Rendering

Red Dot and New Zealand Design Awards Supreme Award the Purple Pin. Also Best Effect for return on investment. CAD Rendering Work done at 4ormfunction 2012

LMI Stacked Rack Rendering

LMI Stacked Rack Rendering

CAD Rendering Designed for cost down and ergonomic improvements. Layout and configuration was designed and engineered by myself from the ground up, working closely with the users. Work done at 4ormfunction 2013

BCS BAGgate - Mark 1 Render

BCS BAGgate - Mark 1 Render

CAD Rendering Work done at 4ormfunction 2012

BCS BAGgate Passenger Interface

BCS BAGgate Passenger Interface

Rendering black Melbourne design Work done at 4ormfunction 2013

Foot Science

Foot Science

Surface modelling and reverse engineering Work done at 4ormfunction 2014

I have used several CAD packages but Solidworks is my closest ally. I have used Solidworks for over 15 years. I am highly proficient in parametric modelling, surfacing and rendering. 

© 2019 by Carl Menary