Portfolio

Max Freeman
The following page shows the work from my work experience placements

ELLER ARCHITEKTEN (GERMANY) HABERDASHERY LTD (LONDON)

Model building to plans of a roof top conversion in Central Berlin. Pewter casting & polishing of the leaves used in a project in Africa, for a royal
household

Casted then polished to reach the

final product/stage

Bone china
 AS Design task: AS Manufacturing:

Design an adjustable lamp for use at a desk/table to provide direct

illumination when working

9 4

3
1 2 10

6 7
5
8

Initial ideas
User Centered Design: Designing to improve the lives of the blind and
those affected by sight loss
Problem:
A common problem facing those with
sight problems is that special equipment
and thorough labelling is required for the
storage of each item in and around the
kitchen. Currently, the market leader is
Penfriend (quick way to identify objects
through braille labels). However, currently
in the UK only 66% have the ability to read
and use braille. Often, everything has its
place and is always put back there
afterwards, this will save a lot of
frustration when you are trying to find
things. This is naturally hardened if you
cant see the labels or identify the
product.
The programme uses voice activation to
indicate the user what is what. This
specific programme speaks to the user
telling them what spice or seasoning it is.
Development & Prototyping:
Programme to improve the day to day
lives of the blind and those affected
with sight loss. Using a basic
programming software which allows
for inputs and outputs, I have
connected a Makey-Makey device.
Manipulating the W-A-S-D-F-G keys, It
can be theoretically hooked up to any
conductive objects around the
household. As an example, I have
created a model of an area in a
kitchen.
The equipment I had available was
very limited. However, major
improvements that I could see as a
real help is designing for recipes.
Whether that is use of dials and
controls or simply weighing out
ingredients.
As an example, sounds or voice
commands can be spoken every time
the user weighs 50g, 100g etc..
Initial ideas for my A2 Project: idea.1
Initial ideas for my A2 Project: idea.2
KEY: Initial Design 3:
Material/Adhesive
On bike view
Process A storage unit designed for paravets to allow them to easily transport their medical equipment and tools to and from location to ensure that it
Property stays secure and safe during transit
Specification Points
Sustainability
3D printed lock

The front door and box frame will be constructed from

wood/plastic composites WPCs. Wood/plastic composites (WPCs)
are made from thermoplastic resins, wood flour, and
wood fiber. Making use of recycled material, Rubber
corner
but all are rot proof. A very sustainable material. Composites have
guards
no defects, and do not compress like wood. Solid composites, dont
splinter and offer good traction in wet conditions. WPC provides no
further finish to combat outdoor conditions or temperatures.

A composite
Sharps box &
screw provides
thermometer Hinges
high shear storage Bolt lock latch
strength with a
high holding
Client Feedback: power.

I feel like this design has a
lot of scope to be a
fantastic design, but my
worry is that the overall
size is too big. The runners
looks great and will make
it easy for the paravet to
get there required
products.
Rubber corner guards have been added to
each edge to ensure no damage is caused to
unit when placed or moved about. It provides
a cushion and will limit any potential
accident. Whether that is during cycling or
carrying. Rubber cement will be used to
connect the two materials together, it
ensures a hard, strong and firm bond.

Degradable
medicine
storage unit

To hold all the paravets 7

different compartments of Sharps box &
thermometer Water
running hinges made out of Degradable box is constructed
storage fillable
3mm acrylic. Each section will acrylic shell out of plywood. Inside fits a hollow
be cut on the laser cutter which acrylic shell which water can be
guarantee accurate, precise 0.5mm tolerance for poured into. Once topped with a
and straight cuts. They will be the housing joint lid it is placed into the box.
connected together with tensol A platform in the central Medicine will be stored around it.
Runners attached Ensuring it is maintained at the
cement with the runner compartment is made to the composite correct temperature during
component being screwed on. using a housing joint wood and acrylic travels.
 KEY:
Final A2 project ways Initial Design: Paravet unit attachment to the pannier rack. Material/Adhesive
Process
Property
that it will attach to Specification Points
Sustainability
All designed units have a flat base so the attachment methods that I will be designing will be universal and can be applied to each storage box.
the bike pannier rack They need to ensure that it can be connected and removed with ease without affecting the performance of the product.

Metal Bracket: Strap: Milled Connector: U Clip:

Two flat U shaped aluminum brackets. The bottom frame
is welded onto the the pannier rack. A nylon nut can be
slotted through the drilled/threaded hole in each corner.
This will allow the paravet to join the top bracket to the
storage unit.
Top aluminium
bracket
Threaded hole
Three layers of plywood are connected together with
nuts and bolts at either corner. The middle layer is split
into three. Leaving two spaced gaps. This will allow for a
buckled strap to be threaded through each entrance
which wrap around the underneath of the pannier rack.
Teak sections will be milled into the two shapes. The
larger C shape will be permanently fixed to the pannier
race. One at either ends facing opposite directions.
C Teak component
(x2)
An 3D printed clip will be connected to the pannier by
being screwed on. The top U shape allows the storage
unit to be easily slid on/off but remain completely stable
and secure during transit.
Bottom U Clip

Upper
plywood Clasping
sheet brackets
Connector (x2)
A semi circular allen key will used to permanently attach
the component to the rear pannier, which slides up and
down

Pannier Pannier
Separated plywood
Bottom aluminium Lower Top U Clip
sheets
bracket plywood sheet
The top U clip will be inbuilt part of the product allowing
Pannier Allen key the paravet to simply slide the whole product on with
Once connected a wing nut can be ease
use to tightly connecting
everything together.
The printed top sheet with the
Clasping brackets slots will be attached to the
are attached to the
Slots in paravets storage unit with cross
pannier using flat
head screws. Multiple will be
headed screws.
used along the surface to
Each corner is connected guarantee a strong hold
with a nut and bolt. To Pannier
ensure that the storage unit
will not fall off the pannier
during cycle journeys. To ensure it is tightly secure a long allen key fits through
the drilled keys. They will be inserted from inside the
Buckle paravets storage unit and will sit flush.
A die will be used to internally
thread the metal brackets and the
unit.

Allen key

Flat top so
will fit flush

Strapped buckle
inserted here
Base of the storage Slotted onto the
unit clips
 KEY:
Development 5 - Pannier: Material/Adhesive
User feedback
Sustainability
I am testing the proposed pannier attachment idea, checking to see if they work and function. Testing the proposed measurements and dimensions

Metal bracket: Strap: Milled Connector:: U Clip::

What am I testing? What am I testing? What am I testing?
What am I testing?
I am investigating the first I am investigating the milled I am testing the U clip pannier
I am investigating the strap
pannier attachment. attachment locking mechanism. attachment
pannier mechanism
Why am I testing it? Why am I testing it? Why am I testing it?
Why am I testing it?
My review stated that I needed I am checking to see if it will work, I am checking to see if it will
Sheet aluminium I am testing to see if it will work
to conduct further research into function and can be easily operated by work, function and operate on
and function.
how it worked. a paravet out in the field the pannier.
What did I do make/model?
What did I do make/model? Pinned on all What did I do make/model? What did I do make/model?
In my initial ideas I stated that I 4 corners and
I created a basic structural centrally Using CAD I modelled the three pieces. I Using CAD I modelled the two
would be using PVA however I
outline using sheet aluminum. then converted it into an STL file so that pieces. I converted it into an
do not believe this is the
This was cut on the guillotine I could print it. STL file so i could print it on the
best/suitable choice. I cut the 2 Upper square
into the correct size then bent 3D printer
squares and 3 strips on a What did I find out?
using the metal bender. I drilled bandsaw which were then
a hole through one corner which pinned on What did I find out?
Straight away i figured milling such a
would be where the nut and bolt
precise piece would be impossible so I It worked and functioned. Once i
will be inserted. Drilled hole, hole would
decided to 3D print it. The first printing removed the wall and filler materials i
have been drilled in
What did I find out? did not work, the sides melted in on could easily slot the two over each
every corner.
each other and the structure collapsed. other. The 0.25mm tolerance was
Testing it on the pannier I found that the structure would Of what I could find out is that I had not correct.
function but could be altered to create a stronger joint. The incorporated tolerances so the slot was
original metal bracket rattled and could potentially damage Three central not wide enough. I decreased the finger
Lower square by 0.5mm, and the gap by 0.5mm on all
and scratch the pannier itself. strips
Using pins makes it fully recyclable sides.
Very sleek design
~ New Solution ~ What did I find out? if they are removed Walls melted and works very well.
New Solution and collapsed You should
I created a bracket U shaped bracket which fit comfortably I found out that it will work and function. The straps once
investigate a way of
inside a square hole underneath the sling. I could optimise this slotted through could easily be tightened, loosened. The The new 3D printed model worked it could slot into each other
connecting it to the
and use it as reinforcement. I drilled holes centrally and either three panels can also be incorporated into the base of any with ease. I discovered the holes did not perfectly match and
pannier itself
side so i could use nut and bolts designed due to its flat nature. the height was not tall enough to comfortably surpass the
aluminum pannier rod. These adjustments will need to be made
On the in the CAD drawings.
pannier
Height was not tall
Very basic, however enough leaving strain
achieves and meets on the plastic
the problem

Holes drilled so I The nut and bolts can be

could optimize the inserted through the flat
sling. sheet of the storage unit
then fixed onto the pannier
What did I find out?
Though it worked I believed it could be further improved. It
still felt a bit shaky and not 100% secure. To combat this i
decide to increase the height of the U shaped metal and drill
holes into the side so that I could use nuts and bolts already
on the pannier
I could
optimize the
unused nylon
nut and bolts
already on the
pannier
Final New Solution
Pannier
The new bracket had the extended/elongated U shape and holes didn't
worked perfectly. Fully secure and did not move. My next step line up.
will be trying to find a way to assemble it to the pannier easier/
quicker and more efficiently.
Fit well,
elongated U
shape.
Once the small
T allen key does not changes are fixed it is
line up, it will need to be a good viable option
The new design looks sleeker extended
and blends into the pannier
A2 Final Idea
Sketches A2 Final Idea CAD
On-Shape
 KEY:
Development 5 - Pannier: Material/Adhesive
User feedback
Sustainability
I am testing the proposed pannier attachment idea, checking to see if they work and function. Testing the proposed measurements and dimensions

Metal bracket: Strap: Milled Connector:: U Clip::

What am I testing? What am I testing? What am I testing?
What am I testing?
I am investigating the first I am investigating the milled I am testing the U clip pannier
I am investigating the strap
pannier attachment. attachment locking mechanism. attachment
pannier mechanism
Why am I testing it? Why am I testing it? Why am I testing it?
Why am I testing it?
My review stated that I needed I am checking to see if it will work, I am checking to see if it will
Sheet aluminium I am testing to see if it will work
to conduct further research into function and can be easily operated by work, function and operate on
and function.
how it worked. a paravet out in the field the pannier.
What did I do make/model?
What did I do make/model? Pinned on all What did I do make/model? What did I do make/model?
In my initial ideas I stated that I 4 corners and
I created a basic structural centrally Using CAD I modelled the three pieces. I Using CAD I modelled the two
would be using PVA however I
outline using sheet aluminum. then converted it into an STL file so that pieces. I converted it into an
do not believe this is the
This was cut on the guillotine I could print it. STL file so i could print it on the
best/suitable choice. I cut the 2 Upper square
into the correct size then bent 3D printer
squares and 3 strips on a What did I find out?
using the metal bender. I drilled bandsaw which were then
a hole through one corner which pinned on What did I find out?
Straight away i figured milling such a
would be where the nut and bolt
precise piece would be impossible so I It worked and functioned. Once i
will be inserted. Drilled hole, hole would
decided to 3D print it. The first printing removed the wall and filler materials i
have been drilled in
What did I find out? did not work, the sides melted in on could easily slot the two over each
every corner.
each other and the structure collapsed. other. The 0.25mm tolerance was
Testing it on the pannier I found that the structure would Of what I could find out is that I had not correct.
function but could be altered to create a stronger joint. The incorporated tolerances so the slot was
original metal bracket rattled and could potentially damage Three central not wide enough. I decreased the finger
Lower square by 0.5mm, and the gap by 0.5mm on all
and scratch the pannier itself. strips
Using pins makes it fully recyclable sides.
Very sleek design
~ New Solution ~ What did I find out? if they are removed Walls melted and works very well.
New Solution and collapsed You should
I created a bracket U shaped bracket which fit comfortably I found out that it will work and function. The straps once
investigate a way of
inside a square hole underneath the sling. I could optimise this slotted through could easily be tightened, loosened. The The new 3D printed model worked it could slot into each other
connecting it to the
and use it as reinforcement. I drilled holes centrally and either three panels can also be incorporated into the base of any with ease. I discovered the holes did not perfectly match and
pannier itself
side so i could use nut and bolts designed due to its flat nature. the height was not tall enough to comfortably surpass the
aluminum pannier rod. These adjustments will need to be made
On the in the CAD drawings.
pannier
Height was not tall
Very basic, however enough leaving strain
achieves and meets on the plastic
the problem

Holes drilled so I The nut and bolts can be

could optimize the inserted through the flat
sling. sheet of the storage unit
then fixed onto the pannier
What did I find out?
Though it worked I believed it could be further improved. It
still felt a bit shaky and not 100% secure. To combat this i
decide to increase the height of the U shaped metal and drill
holes into the side so that I could use nuts and bolts already
on the pannier
I could
optimize the
unused nylon
nut and bolts
already on the
pannier
Final New Solution
Pannier
The new bracket had the extended/elongated U shape and holes
worked perfectly. Fully secure and did not move. My next step didn't
will be trying to find a way to assemble it to the pannier easier/ line up.
quicker and more efficiently.
Fit well,
elongated U
shape.
Once the small
T allen key does not changes are fixed it is
line up, it will need to be a good viable option
The new design looks sleeker extended
and blends into the pannier
A. Disassembly of Chosen Product: Mini Street Cruz

Lower chassis

Handle bar

Upper chassis

PVC
Handles

Steering
mechanism

Connector
Brake
piece

PVC wheel

Connector
insert

Abec bearings have been used to allow for smooth turning

of the wheels. The nylock nut will stop parts undoing due to
friction.

Name: Max Candidate number: 10155 Centre number: 10144 Page: 2

KEY:
Material/Adhesive
Process
Property
Specification Points
Initial Design: Paravet unit attachment to the pannier rack. (cont.)
Sustainability
All designed units have a flat base so the attachments methods that I will be designing will be universal and can be applied to each storage box.
They need to ensure that it can be connected and removed with ease without affecting the performance of the product.

Metal Bracket: Strap: Milled Connector: U Clip:

BRACKET DIMENSIONS: STRAP DIMENSIONS: CONNECTOR DIMENSIONS: FRONT DIMENSIONS OF THE U CLIP:

Top U Clip

Client Feedback:
FRONT VIEW OF THE CONNECTOR DIMENSIONS:
A basic pannier connection
Three tier plywood and attachment method
sheets however, straps are very easy
to use making the life for the
paravets that much easier
Bottom U Clip
FRONT VIEW DIMENSIONS: CLASPING BRACKETS DIMENSIONS:

TOLERANCES:

- TOLERANCES WILL BE PERFORMED TO 1MM

ALLEN KEY DIMENSIONS:
BOTTOM BRACKET DIMENSIONS: DUE TO MANUAL OPERATED PROCESSES
BEING USED TO CUT THE PLYWOOD SHEETS

Client Feedback:

I like the use of the 3D

Client Feedback: printer will it be strong
enough to support
TOLERANCES: A stacking system will 20kg?
work well. I fear that
- TOLERANCES WILL BE the time needed to SIDE DIMENSIONS OF THE U CLIP:
unscrew 4 nuts and
PERFORMED TO 1MM
bolts may take a bit too
DUE TO MANUAL long. Is there a way to
OPERATED PROCESSES make a less permanent Client Feedback:
connection method?.
BEING USED TO CUT
AND SHAPE THE METAL Very intricate but will
be easy to user. I am a
BRACKET fan of the allen key
implementation
TOLERANCES: TOLERANCES:

- TOLERANCES WILL BE PERFORMED TO 1MM - BEING 3D PRINTED ALL TOLERANCE

DUE TO MANUAL OPERATED PROCESSES FLEXIBILITY WILL BE 0.2MM
BEING USED
 KEY:
Final Design: Material/Adhesive
Process
Property
Specification Points
My final development has lead me to my last final design. Taking ideas across our concepts II and III. On the following pages I will Sustainability
show the details of my final design with the aid of orthographic drawings and explanations as to the processes used.

x1 How - The base lay is simply cut to size using a bandsaw.

Base-lay (4)
Assembly - The table is slotted into the routed groove
and is then sealed by screwing in the lay. The curved
sides and backing are then also screwed on using
UNIT #001 countersunk wooden screws to complete the frame of
the unit/

Properties and reasons for the use of the materials is the same
due to stokbord being used for all 4 components.

x1 Why - Stokbord is a low density material but very hard

Table (10) wearing and tough. It behaves like any normal timber
which makes it possible to cut joints very accurately and
makes it suitable for routing due to it being able to be
carved to great detail
Table profile
once it is How - Stokbord will be cut out to form the shape of the
pulled out table which will be cut out on the bandsaw The
underside will be measured and marked to get the
location to where the milled section will be cut out. The
table will then be place inside the base so that it can be
saled with countersunk wooden screws.
Underside
milled section

Overview of the joining processes and connections of the main stokbord unit:

UNIT #001 - OPEN VIEW

2
10

Rebate Joint
formed when the
1 two base
components are Primarily the top piece is
screwed together countersunk and drilled with a pilot
hole. Then a countersunk screw is
screwed in

Small t section can

4 slide up and down
the available space

Push catch can be

accessed from
UNIT #001 - underneath to
EXPLODED initially pull out the
VIEW table
 KEY:
Final Design: Material/Adhesive
Process
Property
Specification Points
My final development has lead me to my last final design. Taking ideas across our concepts II and III. On the following pages I will Sustainability
show the details of my final design with the aid of orthographic drawings and explanations as to the processes used.

Overview of the joining processes and connections of the acrylic degradable storage unit and solids storage compartment:

Each acrylic piece cut out with have

this out lay cut in one end. This will
UNIT #001 allow me to use the finger joint to
connect the two pieces forming the Nut will be
perpendicular shape hand
tightened

Once semi-attached a nut and bolt

can be screwed in to tighten and
fasten the joint.

Bolt inserted
through
pre-cut hole

Magnet
stripps
8 5 attachted to
both parts

6
UNIT #001 -
EXPLODED
VIEW