BEN RAWLINGS

Company: Aesthetic Technology
Location: Warrington, UK

Web: Dermalux Tri-Wave MD (mkII)

European Product Design Award Winner 2023

The Tri-Wave MD (mkII) is a product from the new range of LED based phototherapy medical devices for the Aesthetic Technology brand 'Dermalux', nicknamed 'Gen II’.

In 2019 the company developed the Tri-Wave MD (mkI), the most powerful LED phototherapy device in the professional market. The mkII device has been developed to bring the product into alignment with the company’s new overarching design language while simultaneously pushing boundaries with developments in efficiency and performance.

The modular design shares componentry with the other products in the range that has allowed for a flexible production approach that has improved efficiency and overall product quality. Aesthetic Technology have been developing LED phototherapy products for 10 years. The ‘Gen II’ range is the combination of the learning and development over this time period providing state of the art LED phototherapy.

The Tri-Wave MD (mkII) utilises a large, adjustable, 4-pod head to deliver LED phototherapy treatments to broad areas of the skin. The devices are designed to treat numerous dermatological skin conditions through the medium of precisely toleranced, high power LED light output. The programmable light wavelengths from the device are designed to penetrate to different levels of the skin for various functional benefits. The devices provide different power levels and programmability based on clinical requirement.

The clinical setting was carefully considered in the development of this product to minimise the overall footprint of the unit while also providing a highly mobile device with a clean and minimal aesthetic to suit the clinical/medispa environment it would be used in.

The products in the 'Gen II' range are all class IIa certified medical devices developed within an ISO 13485 and tested to meet the requirements of EN 60601

Company: Aesthetic Technology
Location: Warrington, UK

Web: Dermalux Compact

European Product Design Award Winner 2023

The Compact MD and Lite were the first devices released in a new range of LED based phototherapy devices for the Aesthetic Technology brand 'Dermalux', nicknamed 'Gen II'.

The devices are designed to treat numerous dermatological skin conditions through the medium of precisely toleranced, high powered light output. The programmable light wavelengths from the device are designed to penetrate to different levels of the skin for varying functional benefits. The devices provide different power levels and programmability based on clinical requirement. The device outputs 3 wavelengths of light, Blue (415nm), Red (633nm) and NIR (830nm). These can be taylored and customised via the device UI to treat skin conditions such as acne, redness, psoriasispsorisas, pigmentation, inflammation, wound healing and musculoskeletal pain.

The products in the 'Gen II' range are all class IIa certified medical devices developed within an ISO 13485 and tested to meet the requirements of EN 60601.

'Gen II' looked to establish a new design language for the company that would provide a statement look whilst simultaniously making big improvements to production efficiency and product quality.

The approach of the project from the outset was to develop a suite of products that were a lot more light-touch and easy to use and understand than previous devices the company had developed. They were to allow for modular manufacture and capitalise on commonality of parts to streamline the purchasing and production processes.

Client: Jones & Partners for Connection Furniture
Client Location: Huddersfield, UK

Web: Connection UK

The Freedom work wall was designed to promote a dynamic and highly functional workspace with the ability to create impromptu meetings and work collaboratively. The scope of the project was to develop an multifunctional product that was completely mobile and untethered for use anywhere in the office.

The initial concept of the designed focused around utilising common steel side panels that could then be crossed-braced with different connecting frame elements to create a structure that would allow for modular manufacture and commonality in parts. From here a number of product configurations were created including:

• A media wall that would house a large format screen with in-built power inputs and outputs.

• A dry-wipe pall wall

• A shelving and storage wall

The Freedom wall was designed to integrate into the modern office with slim profile and a clean, simple overall aesthetic achieved with premium materials and textures. The product also has the option of being fitted with sound dampening acoustic panels, critical in modern work spaces.

A common issue for work walls such as this is access to power and they unit consistently needing to be tethered to a socket. We developed a large format battery and inverter system for the unit that could allow the device to be powered throughout the day and have no limitations on mobility.

Client: Jones & Partners for Connection Furniture
Client Location: Huddersfield, UK

The Telephone Pod for Connection Furniture is a systematic, flat-pack, easy installation privacy pod for commercial offices. The modular approach allows the product to be sent to site as a series panels that are simply bolted together for rapid installation. The simplistic, clean modern design provides high levels of acoustic dampening as well as a fully in-built electrical lume that automatically powers the pod when someone enters.

The idea of utilising an aluminium extrusion framework was quickly identified in the initial ideation stage. The extrusions would allow for panels to be created that were lightweight, easily put together and structurally sound so that they could then be cladded in various materials.

Numerous prototypes were developed to test out key functions of the design and refine the assembly process. All aspects of the product were tested and refined through the prototyping process. Acoustic performance was a key metric for the success and therefore acoustic testing was performed with each prototype build and steps were taken to improve the acoustic performance within each stage of development.

The assembled panels ultimately used acoustic foam that could be sandwiched between multiple material options for sound dampening. The final acoustic testing on the product before production saw a 31db noise reduction inside the pod from external noise and there was a 29db noise reduction from sound coming from inside the pod.

The product utilised a custom electrical lume that was built into the panels that used a PIR sensor to activate the LED panel light when entering. It also provided power to a gang of desk mounted sockets so that laptops, phones, tablets etc could be charged while the pod was in use.

Following the prototype sign-off a full production pack was handed over to the client consisting of engineering and assembly drawings, 3D data, BOM and volume pricing. The sub-assembly panels were built in-house, in Connection’s factory and then shipped to site meaning the cost of on-site assembly was drastically reduced.

Client: Jones & Partners for Aircharge
Client Location: Oxford, UK

Web: Aircharge

Jones & Partners developed and understood at an early stage the importance of technology integration into offices and public places to the ever more interconnected world. Jones & Partners developed a brand-defining portfolio of products based around the, then-emerging, wireless charging interface for technology brand, Aircharge. The suite of products focused on the need to provide an intuitive, seamless integration into the user’s lives by breaking down all barriers to adoption and understanding.

Joining the project at the later stages of development I worked with Aircharge to develop and productionise the existing suit of product developments. Working through the DFM process, production sampling and solving quality issues. I then also designed and developed the next generation wireless charger the ‘Surface Charge 2’ - working on this project from its inception.

The product range included various wireless charging devices that were adaptable for different commercial and domestic situations:

Battery technology to untether the user with integration into mobile or isolated furniture

Various wireless charging solutions developed to be stand-alone or mounted into various furniture pieces.

An ‘Orb’ and key-ring adaptor that allowed users of any phone, regardless of whether it had wireless charging capabilities or not to utilise the technology

A desk mat with integrated wireless charging that turned a standard work station into one that provided comfort as well as seamless and subtle integration with the users devices.

Various accessory devices, mounts and organisational elements to further break down any barrier to adoption.

The product range was widely praised. The ‘Orb’ adaptor product was one of the few products to have passed Apple’s MFI certification and is the only certified triple headed charging device on the market. As a result, Aircharge became a recognised and approved certified global partner to Apple.

The development of these products infused industrial design, electronic development and user experience to create a range that took an emerging technology and contextualised it to a an easily consumable and understandable package for Aircharge’s customer base.

Client: Jones & Partners for CMS Electracom
Client Location: London, UK

Web: CMS Electracom

CMS Electracom are an electronics manufacturer operating in a very cost-competitive market, primarily supplying the office fit-out industry. This portfolio of devices was born out of a strategic review of the current market to identify an opportunity for a new range of products that would stand-out amongst the crowd and be a more premium offering. The range aimed to provide a more tactile, mature, design-led approach than the competition, utilising specific design detailing and soft fabric elements (a trend seen in the consumer market) to, more appropriately, blend in with the modern office environment.

Jones & Partners took the product range from inception, through to prototype and into DFM and production. Leading the project from the start, I began by creating a broad range of concept ideas with a unifying, modern, design language. From here a range of iterative, 3D printed prototypes were created to develop and test the critical functional aspects of the product before engaging in the DFM process.

Power Rail:

The Power Rail was designed to provide modular rail system that could be configured to suit the requirements of the customer. We paid special attention to the detailing around the front fascia of the product utilising intentional shadow gaps that would ultimately define the overall aesthetic of the range. The rail system houses modular power blocks that can be configured at the point of order to include AC and DC power options. From here a series of different mounting methods were developed to provide a truly versatile offering.

Portal:

The Portal product was a puck that would be mounted into desk grommet holes. The unit would house CMS Electracom’s existing AC socket module and 100W USB-C module. It was design to be retained into the desk surface with minimal protrusion on the underside, making it suitable for mounting into folding desks.

Quibit:

Quibit provides USB-A and 100W USB-C charging. The small unit with reversible mounting bracket can be mounted either above or below a hard surface. The small footprint of the product is designed to provide power with minimal intrusion on the desk space.

Available as a single or double unit, the product was designed to minimise production cost but also provide high level design detailing. The range-defining shadow gap around the fascia of the product breaks up the front surface so any misalignment with USB modules is visually minimised. The casing of the product is very simple and made up of two injection moulded pieces that are screwed together.

Client: Jones & Partners for Task Systems
Location: London, UK

Web: Task Systems

Mixology Award Finalist in 2018 and 2019

The Arc product range was designed with PWC and Task systems to address the evolving need for collaboration in modern offices.

The original project was to develop a multi-functional mobile work wall that would provide a highly mobile solution for impromptu meetings and discussions. Launched in 2018, the Arc 1000 provided space division, a large writing surface, storage and acoustic dampening. It was so well received that it was nominated for a Mixology award and immediate demand for an expanded range was recognised to increase the capabilities and versatility of the product.

Leading the project from it’s inception and especially in it’s engineering development, I worked directly with joinery suppliers, electrical suppliers and PET cutting and thermo-moulding suppliers to develop a wide variety of in house prototypes and test rigs to develop the functionality and design language of the product before heading into full UK based production.

Now in full production, the expanded range of product includes:

Arc 1000: The original product that provides space division, storage acoustic dampening, whiteboard surface and pinboard

Arc 2000: 2m wide version of the original Arc unit that can divide large areas and be used to create meeting areas.

Arc Media: A 2m wide mobile conferencing unit capable of holding and powering up to a 55 inch screen. The unit has a custom designed battery unit internally that powers the screen for untethered mobility.

Arc Window: A 2m wide social, collaborative addition that provides a standing desk in built wireless charging that is again battery powered.

Arc Plantation: Similar to the Arc 2000, it provides large format space division with the addition of 2 planters that provide greenery to the office.

Client: Biome (Freelance)
Location: California, USA

Web: Biome

Biome approached me following the the development of a unique air filtration system and monitor that utilised the natural oxygenation effects of indoor plants and used fans and sensors to monitor and improve the air quality of a given room. Targeting public spaces and offices, the use of Biophillic design has many scientifically proven benefits for office workers such as reducing stress, improving productivity and regulating the circadian rhythm.

Looking to develop the system into a functional product that could be wall mounted or freestanding, I worked with them to develop the internal structure, assembly method and to produce two premium sheet metal structures (portrait and landscape) to house the system.

Working across borders with their existing supply chain in California, I developed the structures and produced the relevant production data for their sheet metal suppliers to create. Working with them directly we produced a number of revisions and prototypes to refine the design to meet functional and cost requirements.

In addition I also aided in the development of the plastic injection moulded internal plant holders and helped to refine and improve the optional lighting bar they would be including with the product.

Company: Plumen
Location: London, UK

Web: Plumen

A modular range of easy-to-install accessory products to accompany the main light bulbs sold by Plumen. This provides a diverse range of setup options and solutions to improve customer engagement while expanding the product offering significantly. The primary functional aim with this range was to create a range of products that could be easily installed.

Ceiling Hook:

With many Plumen installations, customers would use an assortment of DIY methods to loop pendant cables to either create an interesting display or relocate the pendant’s light fixture away from the ceiling rose.

The design utilised a barrel shape would provide a good aesthetic for the design as it could hide the fixings when installed and look relatively seamless with the ceiling or wall.

The final concept design utilised a knurled thumb screw that could easily be tightened/loosened by hand to allow for easy adjusting once the cable had been fed through. The two part design consisted of a machined aluminum bar and a thumb screw. The machined bar required three milling operations to hollow it out, create the cable slot and tap a thread for the thumb screw.

Drop Top Lamp Shade and Mounting Ring:

The brief was to design a glass lamp shade that could be retrofitted Plumen’s standard pendant luminaire, without having to remove and reinstall the pendant. This would allow for customers to easily attach the shade to their previously purchased products.

Several glass shapes were designed to establish a desirable aesthetic. From here, the potential dimensional tolerance variations from the glass manufacture process (hand blow moulding) were simulated to gain an understanding of how the glass could sit at different heights on the pendant.

The idea for a mounting ring was developed that could be attached and tightened around the bottom of the pendant to create a mechanical mounting point for the glass shade.

Following several iterative rounds of prototyping for the mounting ring, the final engineering drawings were created and sent to the manufacturer for production sampling and tooling. A sample silicon tool was created for the glass shade and prototype parts were created. Due to the glass being hand-blown, there was a large tolerance variation in the glass opening so several were tested to ensure it sat on the mounting ring correctly.

Company: Plumen
Location: London, UK

Web: Plumen

The Plumen 003 is a unique LED lamp design that uses a patented central structure, an arrangement of faceted brass elements around clear, polycarbonate optics, to create an alluring distribution of omni-directional light. During it’s development it was realised that a pendant would be required to create a complete luminaire. It would need to match the bulb’s premium aesthetic and provide an easy method of installation.

Working closely with the companies creative director, the general form of the pendant design underwent many initial design iterations. The design needed to follow the curvature of the bulb which would eventually produce the unique concave shape of the pendant.

It was realised early on that the lamp holder cover should be made from steel for the continuity of the brands design language. Due to the concave shape of the design, the concept was developed with the aim of being manufactured using a spinning process. Liaising throughout the process with the manufacturing supplier in China, it was established that a collapsible core could be used with a two-part tool to achieve the shape required despite the undercut.

A custom mounting bracket was then designed and added to the ceiling rose assembly. This allowed for easier installation as the mounting bracket could be mounted to the ceiling while the pendant was being wired in.

Several functional prototypes were created to allow for minor dimensional adjustments and alterations. Ventilation was added to the top of the lamp cover and proved to be effective in cooling the unit.

All of relevant manufacture drawings, manufacture specifications and general assembly drawings were created and the spinning tool for the lamp cover was commissioned. Following this process several rounds of FAI sampling were conducted to work out the various manufacturing quality issues.

Finally the product was CE, TUV, ETL and PSE certified for different global markets.

Company: McCue Corporation
Location: Milton Keynes, UK

Web: McCue

Distribution centres and warehouses are always busy with various vehicles, equipment and heavy loads being manoeuvred. It is therefore essential to protect the structural columns within these areas to ensure a safe working environment.

The Barrel Guard is a simple to install, high-impact protection product for columns. The modular, hollow polyethylene body components provide an air-cushion that delivers very high levels of strength and durability to protect columns from impacts. The modular components of the product are adjustable to suit a wide variety of column sizes and are held together with a high-strength ratchet and strap system. The four corners of the body interlink and are created from just one rotational moulding tool.

The project brief was initially to design a lamppost protector. The company was buying in a third party product to sell to customers and there was a recognised need to create a version of the product that would eliminate these 3rd party costs and improve the design to be more robust and protective.

The initial concept designs focused on creating a modular product that could be adapted to different heights. The design used symmetrical components which meant that only one tool would be required during manufacture. It would also allow for extremely quick and simple on-site installation.

Upon review of the concepts it was realised that the modular, one tool design could be applied to a ‘column protector’.

The company was currently working on and producing a range of protection products for warehouses and distribution centres. Due to the robust design of the concept, the project was re-purposed to produce a product that could protect internal columns from high-strength impacts from vehicles such as forklifts and lollops. The design was developed to meet this criteria, using a stronger fixing method and a four corner modularity system to allow the concept to be adjustable in width as well as height for a broad variety of column sizes.

A number of concepts were developed working closely with the company’s rotational moulding supplier to understand the technical feasibility of the complex shape of the corner components. The modular corners are held together using a 50mm ratchet and strap system - this is capable of holding loads of up to 1 tonne. The design is expandable for use with column sizes from 100 x 100 to 300 x 300 - rectangular shapes can also be accommodated.

The developed concept was drawn and a rotational moulding tool was created from it. A series of FAI’s (First Article Inspection) were used to assess and correct tolerance, surface finish and shot weight issues.

Following the FAI process product samples were created using MDPE and HDPE so that the material could be tested to determine the right amount of deflection under impact. Due to the higher density, HDPE is more rigid than MDPE.

The product was tested by TUV, an international testing standards company to meet BS 6399, using a pendulum test. A 500lb pendulum was used to impact the Barrel Guard, traveling at a speed of 3ft/s. It was found that the HDPE version of the product could take a greater impact. The final result was that the Barrel Guard could withstand an impact of 900 ft-lbs without any visible damage. This translates to a 2955kg vehicle traveling at 2mph - exceeding the BS 6399 standard.

Finally, a patent was filed by McCue for this product based around it’s function and modularity. Myself and one other are named as inventors on the patent. The patent was granted.

Client: Passel (Freelance)
Location: New York City, USA

Web: Passel

The team from Passel approached me with their product following a successful Kickstarter campaign. They had built the infrastructure for a VPN router to protect the users privacy and block malicious ads. By building this software into a router, the device would automatically provide the benefits of the VPN to every device connected without needing to install software on every device.

Passel were looking to develop a design that was low-cost, allow for easy assembly with the PCB while also being refined and aesthetically pleasing.

With this in mind several early sketch concepts were developed and the unique cylindrical shape was defined with ventilation and branding detail on the top of the device.

The housing was developed to be made of two parts that were plastic injection moulded. They utilised internal snap hooks to remove the need for screws or other hardware while also maintaining a clean outside surface and aesthetic. The housing utilised tight-tolerancing and rib features to hold the internal PCB with no fixings to again allow for quick and simple assembly. Finally, the design cleverly minimised the visibility of the split line between the parts.

The design was developed and tested with a series of 3D printed prototypes before moving forward to a China-based injection moulding supplier.

The relevant production documentation was created and several sampling rounds were conducted to resolved some material flow and sink issues that presented themselves. Once happy with the final injection moulded samples, the product went forward into full production.

Passel later came back to me to design and develop their follow up offering; a more powerful VPN router, Beam.