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DevelopmentThis is the design that I have chosen to develop and ultimately manufacture at the end of my project. During my initial design process I developed this idea slightly with the stand being curved. However, I will now look into this design in adequate depth and look at the manufacture, usability, materials and components as well as the aesthetics of this design.

After reconsidering points raised within my research and further specifications I have found that I have two clashing design themes, modernism and organic design. Although I played with the idea in my initial design process of having a curved stand to make the product look more organic, this shape would coincide with the straight edges and corners of modernism.

What I must now consider is which theme is more important to my product, brief and brand I am designing my product for. After reading through my brief I have decided that modernism must take a priority in the design, as KEF’s product represent this movement and as I am designing my product for them, mine must fit into their product base. My brief also specifies that my product will be based on modernism, but take inspiration from nature and organic shapes, which I have already done with the dome shaped cover for the speaker.

After this development I experimented with shapes that I could use as the stand. In the end, I opted for the overly simplistic ‘C’ shape that I have seen used in countless modernist products.

An additional benefit of using this shape for the stand is that it will be more user friendly. This is because the product could be moved easily and quickly. This is in comparison to the curved back, which would be difficult to move with just one person, therefore could have posed a safety hazard. You can see from the two images below that the curved shape is more difficult to manage and hold.

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DevelopmentContinuing the idea of simplicity that has come about from research into modernism, I feel that I can further limit the complexity of my design by reducing the number of materials I will use. The problem I have is that during my questionnaire I found that wood was the most popular material, however metal would be more preferable to keep in my product as it is key to a modernist design.

After researching existing audio products and modernist products in their environments, I found that many of them did include metal in there makeup, but still suited their environment, which commonly featured uses of wood e.g. wooden floors. Because of this I will be removing wood as a material to use in the manufacture of my product and instead have the whole stand made from metal.

Although I have decided what material to use I will now further develop this idea with deciding on what metal to use, as different metals will have different properties as well as aesthetics. The two metals I thought would be best suited for my product would be aluminium and steel because of there availability. I have created a table which features the properties of each of the metals so that I will be able to decide on which material would be best suited to its purpose in this instance.

Steel Aluminium

Poor resistance to corrosion

Good strength to weight ratio

Malleable Light

Good tensile strength

Attractive finish

Ductile Ductile

From looking at the table I can see that although some properties are similar between the two metals the attractive finish and good strength to weight ratio of aluminium would be more desirable for my product.

As aluminium is the choice for the metal I will be using, I think it is an appropriate to look into the manufacture of this material further so I can gain an understanding of how long manufacture will take and if I will have to alter the design of my product to make it possible to shape or join this metal.

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DevelopmentAs I have looked at the aesthetics of my product I must now think about the manufacture of my speaker, especially how components will fit together, and how this may effect my the design of my product.

Initially I went back to some of my very first research, audio product decoding. Here I looked into how speakers are put together and took apart an existing speaker to gain first hand knowledge of how they are put together. What I realised from this was that I would have to manufacture my own housing for the speaker. To make a break from the straight lines of the frame and for practicality I will make a case that is circular and to ensure that the materials I use are limited I will use aluminium as the material for the housing.

When creating the shape of the housing for the speaker I realised a potential problem with how I would secure the housing of the speaker to the frame of my product. One solution would be to have the housing glued to the frame with an adhesive glue. Although this would be the easiest and quickest way of securing these two components I would be cautions with how well the adhesive would hold the housing to the frame. If the adhesive wasn’t strong enough there could be a massive safety risk if the speaker was likely to fall off.

The alternative would be to cut a hole in the casing and allow the housing rest on the frame by mounting the housing onto the frame. Although this could potentially increase the manufacturing time considerably the structure of my product would be a lot stronger and secure.

Because the price tag on my product will be suitable for a well off customer base my product must be of the highest quality and must be well made. Because of this I will be going for the option to have the housing of the speaker mounted onto the frame. As I needed to be sure of how the manufacture of this idea would be carried out I have made a blown apart diagram showing all of the components.

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DevelopmentWhen looking at an image of my product so far I realised a construction fault, which was the distribution of weight over the frame. Depending on the weight of the transparent cover my product may not be able to stand on it’s own. A solution to this is to move the bottom of the stand further out so that it is level with the bottom of the cover.

As well as creating a better balance to this design, which has improved the safety and usability of my product, it has also altered the aesthetics to create a more prefect and square shape to it, which adds to the simplicity of the design that in turn further creates a beauty through simplicity.

However, after some thought on how to simplify the design to make the manufacturing process quicker and easier, I realised I could remove the aluminium arm that comes out to mount the speaker on. Instead, I thought the speaker could be mounted straight onto the housing of the speaker. This would further improve the weight distribution and thus safety of the design. However, I would still be able to keep my previous development of having the bottom part of the frame extent further out as shown in the design below.

Because of this new development I must now reconsider how the housing of the speaker will fit onto the frame. Although I first considered my original idea of having the housing slot onto the frame, the change in angle, i.e. from horizontal to vertical, would cause pressure to be applied to the speaker from the frame.

After some initial ideas of how I would be able to join these two components I came up with two possibilities. One was to have a tapping screw going through the metal tubing of the frame and the housing as demonstrated in the ProDesktop design.

The other option would be to manufacture a plug that would fit into the top of the metal tubing of the frame. I would then be able to cut a thread into the plug as well as the inside of the housing, which I would first have to cut into to create a hole. The plug would then slot into the top of the frame and then screw into the housing. Although this would the more complex idea to construct I feel that it would be the most secure and accurate option. Additionally there would be no aesthetical defects which would inevitably occur if I was to have a screw visible going through the housing.

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DevelopmentThe aesthetics of my product is absolutely key, with the addition that many people will buy a product on the aesthetics along, which I discovered during my questionnaire. I stated in my questionnaire I would do further research into the design theme modernism, which I visually represented in my mood board. After comparing aspects of this design theme I believe it fits into my brief as well as the KEF product base, therefore I will bear in mind this design theme throughout the initial design process of my project. An additional piece of research where I focused on the aesthetics was brand profiling. Here I researched whether products are reflective to the brand in the profit and aesthetics; which I found the majority did. Because of this it is vital that I feature KEF’s sleek and high quality appearance that all of their products portray in my product.

During the part of my research called product profiling I discovered visually represented where I hoped my product would fit in the speaker market. I located my product in the higher end of the table which suggested my product would be modern and expensive. When looking at existing products that were also in the category many of them promoted the design theme modernism, which I will be featuring in the design of my product. This has convinced me that my product is at the correct pricing for the design and quality of materials I will be using.

Although I have specified my target audience as a well off, middle age market, there were some points that arose during the environmental snapshot part of my research that I need to address for a more general audience. I will be including a 3.5mm jack or an Apple specific jack so that users are able to plug their audio device into my speaker, such as an IPod or IPhone.

Despite my product having to be eye catching I also need the product to suit the environment that it will be displayed within. In my first-hand existing design analysis I discovered that many products didn’t need to stand out as the well known brand that had manufactured them would be enough for someone to buy the product. As mine won’t have this luxury the design has to be eye catching, however I am determined to stick to the design theme modernism and I also must bear in mine that the environment will most likely be a modern apparent, which when look at in my mood board consists of very neutral colours. Because of this I will have to use colours such as black, white and grey, however my product will be unique and eye catching through the shape and size of it instead.

Although safety features must be considered I am very unwilling to include any that may interfere with the aesthetics of the product. Because the design theme modernism includes a lot of straight, sharp corners and edges it seems unlikely that I will be rounding them off. However, as my target audience is of a mature age I would expect them to be aware of potential dangers such as the weight of my product as well as any sharp edges and corners.

As my product will be expensive in price the size will not be limited by prices of any potential materials. Additional I found in my environmental snapshot that other audio products weren’t being used as speakers, but more ornaments. Although the prime function of my product is to be able to play music, the look of my product must also be of a unique and high quality bearing in mine this information. Because of this I will design my product as a stand allow speaker so that it will be a more prominent feature within the environment it will be placed in.

I have specified throughout my research and within my brief that I would focus more on the aesthetics rather than the function. However, when I looked at my brand profiling I found that all products from each brand represented the brand and the values. Because of this I will include an innovative function, such as 360° sound, to improve the sound quality, however the technology will be one that KEF will already have used.

Despite wood not being a prominent material within the design theme modernism, it was the most popular material during my questionnaire. Although I will include it as a potential material in some initial designs it may have to change during the development process as it doesn’t suit the design theme modernism.

Development completedUnable/not willing to developNot yet addressed development

Like I expected to see at this first checkpoint, it would seem that many specifications raised have already been addressed. However, this would suggest I have addressed the most evident developments including the aesthetics of my product.

Some points I have realised that I cannot included in my final product, for example considering any safety features that may hinder the aesthetics of my product. This would not only co-inside with my brief, but many of KEF’s product that haven’t had edges or corners rounded.

Points I haven’t addressed yet included the manufacturing processes of many of the components as well as the functionality of my product as I still haven’t decided on what or even if I will include an innovative function.

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DevelopmentNow that I have looked into some depth of how the exterior of my product will fit together and be manufactured, I must now think about the electronics. The importance of this is evident as my product must be able to work and for fill it’s primitive function, to play music.The model below visually demonstrates how the wires will follow from the speaker all the way to the power source and the auxiliary extension.

The housing is where my speaker will sit. Therefore I will need to drill a hole through the bottom so that I am able to run the wires from the speaker through into the hollow metal frame of the product. I will drill this hole with a pillar drill using a drill bit that fits the size of the wires.

As I have not yet decided on how to join the frame together I can only assume that it will either be with some kind of metal jointing process such as mid welding or brazing, or with a plug similar to the housing of the speaker. Therefore the wires will have no trouble passing through this section of the design.

The speaker cover when first manufactured will have a solid base and therefore mute any sound trying to pass through it. Because of this I must create a hole in the cover where the speaker can be exposed fully to ensure that the sound isn’t muffed. I will further explore how I will cut this hole and what material the cover will be manufactured from later in my development. Before the wires are able

to flow through the frame, they must first pass through the aluminium plug that I developed earlier in the process. Like the housing I will also need to drill a hole to allow the wires through, which I will do before cutting the thread into the outside of it so that it will be easier to clamp down when drilling.

For the power source I have opted for a standard plug socket extension that will extend from the bottom of the frame at the back. Although I believe this has some visual impediment on the aesthetics of my product this is an unavoidable feature and one that I didn’t mention in my brief as it didn’t seem like an important issue to many users. To allow the wire for the plug to extend out of the frame I will again drill a hole underneath the frame to allow for this to happen. The auxiliary cable will also be able to pass through the hole so that IPod can be used into the speaker.

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DevelopmentAt this stage in the development I think it’s important to address some of the issues raised on the last page of this process as I realised there is still many things that need to be considered.

One of which is how the frame will be joined together. The obvious choice would be to use the same joining process as how I intend to join the frame to the housing of the speaker, which involves a plug with a thread cut into it allowing the components to screw in together.

An alternative would be to use some sort of welding, brazing or soldering process. Below I have experimented with all of these processes.

To then give the metal an attractive finish I will file and sand down an excess where I have brazed the poles together. After assessing the finish of the metal pole I sanded and polished I found it very attractive and suitable for how I want my product to look.

So the overall frame has a clean and shiny finish I will use the metal polish machine to clean of any dirt that has built up over time.

Here I have soldered to aluminium poles together. Although this process is reasonably accurate and fast the joint is very unstable and weak. Therefore this process is not suitable for my product.

The only other option I am left with is brazing. Unlike soldering the joints are stable and sustainable and unlike mid-welding the appearance is a lot more discrete. When attempting to join the two metal poles I also found this process reasonable simply and fast to do.

Because of this I will be using brazing to join the frame and after some further experimental work with this joining process I decided that it would also be suitable to use for joining the frame to housing rather than spending a long period of time manufacturing a plug and then cutting a thread into it.

Mid-welding was another option and unlike soldering creates very sturdy joints and is often used for the frames of tables and chairs. However, unlike where the joints are made on tables and chairs the area that the welding will take place on my product will be visible to the user. This is an aesthetical problem as mid-welding is notorious for being a difficult process that creates noticeable and unattractive joints. Because of this, mid-welding will not be used in the manufacture of my product.

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DevelopmentAt this point in the development I also realised I hadn’t specified how I would manufacture the housing for the speaker, even though I have gone into detail about how I will join it to the frame.As casting would seem the obvious choose for how to create the housing I researched into some potential casting methods I could use.

Sand casting

Gravity die casting

After looking at the speed of each process and which ones were readily available to me I concluded that sand casting would be the best method of casting for the housing.To gain a better understanding of how this process works I have attempted to carry out the process and look at the steps involved.

Finally, to create the hole of wear the speaker will sit I thought about drilling it. However, after looking at the sizes of the drill piece available to me I realised I would not be able to create a hole big enough for the speaker. Instead I will look to using a mandrel which will be pushed through the centre of the block.

As the final product after casting is rather unattractive I will use the milling machine to remove the ruff and dirty surface. I have decided to use this process instead of sanding or filling as it will be quicker and create a more attractive finish in a shorter space of time.

Find correct size drag

Parting powder and backing sand in two halves with moulds

Bolt drag and the cope together

Melt aluminium and pour into mould through rise or runner

Metal allowed to cool, sand removed for final product

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After a rethink of how this component could be created I rethought what material to use as using a polymer seemed unlikely. Instead I considered using glass.

One way in which I would form the glass to the shape I want would be to use the process slumming, where the glass is heated up over a moulded and allowed set over the mould.

When the glass cover has been manufactured I would then need to think about the how to cut the hole that will allow the speaker to project the sound it will produce. As a normal drill would be unable to cut through glass without cracking or damaging it, I will need to order a special glass drill piece. A benefit of order this drill piece in is that I will be able to order the exact size piece I need to fit the size of the speaker.

One of the last and most crucial components I must consider within my development is the domed shaped cover for the speaker. This component is key to the aesthetics of my product and therefore in for filling the brief for my product.During my initial design process I assumed that I would be able to vacuum form this component. However, two problems I am faced with included not having a polyester sheet thick enough for how I want it to be. Additionally, the vacuum former available to me isn’t big enough to create the size cover I would want for a floor speaker.

The alternative would be for a specialist to blow the glass for me. This process, although expensive, would be ideal as I would be able to create the shape and size I want the cover to be as well as it having a professional finish and look.

The last development of this component is how I will attach it to the rest of the product. Although I was hoping to use an additional process where I would be able to remove any excess traces of the joint. However, I now realise that for materials like glass and aluminium this is not possible.

Alternatively, I will be able to use screws and although I was hoping to avoid using this joining process I feel that it is necessary for the safety and stability of my product.

The way I will conduct this process is with four holes evenly spaced out that I will drill through the glass and into the aluminium housing. I will then use a screw similar to that of a nut and bolt, called a machine screw. These will screw into and through both components .

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DevelopmentThe aesthetics of my product is absolutely key, with the addition that many people will buy a product on the aesthetics along, which I discovered during my questionnaire. I stated in my questionnaire I would do further research into the design theme modernism, which I visually represented in my mood board. After comparing aspects of this design theme I believe it fits into my brief as well as the KEF product base, therefore I will bear in mind this design theme throughout the initial design process of my project. An additional piece of research where I focused on the aesthetics was brand profiling. Here I researched whether products are reflective to the brand in the profit and aesthetics; which I found the majority did. Because of this it is vital that I feature KEF’s sleek and high quality appearance that all of their products portray in my product.

During the part of my research called product profiling I discovered visually represented where I hoped my product would fit in the speaker market. I located my product in the higher end of the table which suggested my product would be modern and expensive. When looking at existing products that were also in the category many of them promoted the design theme modernism, which I will be featuring in the design of my product. This has convinced me that my product is at the correct pricing for the design and quality of materials I will be using.

Although I have specified my target audience as a well off, middle age market, there were some points that arose during the environmental snapshot part of my research that I need to address for a more general audience. I will be including a 3.5mm jack or an Apple specific jack so that users are able to plug their audio device into my speaker, such as an IPod or IPhone.

Despite my product having to be eye catching I also need the product to suit the environment that it will be displayed within. In my first-hand existing design analysis I discovered that many products didn’t need to stand out as the well known brand that had manufactured them would be enough for someone to buy the product. As mine won’t have this luxury the design has to be eye catching, however I am determined to stick to the design theme modernism and I also must bear in mine that the environment will most likely be a modern apparent, which when look at in my mood board consists of very neutral colours. Because of this I will have to use colours such as black, white and grey, however my product will be unique and eye catching through the shape and size of it instead.

Although safety features must be considered I am very unwilling to include any that may interfere with the aesthetics of the product. Because the design theme modernism includes a lot of straight, sharp corners and edges it seems unlikely that I will be rounding them off. However, as my target audience is of a mature age I would expect them to be aware of potential dangers such as the weight of my product as well as any sharp edges and corners.

As my product will be expensive in price the size will not be limited by prices of any potential materials. Additional I found in my environmental snapshot that other audio products weren’t being used as speakers, but more ornaments. Although the prime function of my product is to be able to play music, the look of my product must also be of a unique and high quality bearing in mine this information. Because of this I will design my product as a stand allow speaker so that it will be a more prominent feature within the environment it will be placed in.

I have specified throughout my research and within my brief that I would focus more on the aesthetics rather than the function. However, when I looked at my brand profiling I found that all products from each brand represented the brand and the values. Because of this I will include an innovative function, such as 360° sound, to improve the sound quality, however the technology will be one that KEF will already have used.

Despite wood not being a prominent material within the design theme modernism, it was the most popular material during my questionnaire. Although I will include it as a potential material in some initial designs it may have to change during the development process as it doesn’t suit the design theme modernism.

Development completedUnable/not willing to developNot yet addressed development

As I have focused the last 20 development on the manufacture of my product and how components would fit together it would appear that little has been addressed from my further specifications. However, during these developments issues such as safety, cost and aesthetics were all considered and therefore I have maintained all of the developments I achieved in the previous checkpoint.

From what you can see highlighted in white lettering there are still points within my further specifications that I haven’t addressed yet. Therefore in my next 10 developments it is crucial that I address the functionality of my product e.g. the output to use for the audio device, the set up of the speaker and if I will be including an innovative function.

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The obvious choose would be to use an auxiliary cable. These are widely used and would allow me to plug in both an IPod and MP3 player.

Alternatively, I can use the jack that is unique to Apple products. Although I wouldn’t be able to connect an MP3 player with the output directly, Apple products would be the audio source for the vast majority of music being played through my speaker. Additionally, this output would allow an IPod or IPhone to stand up whilst being used to play music as demonstrated in the picture from a docking station I personally own.

The other potential idea I came up with was to use Bluetooth technology to allow music files to be played through my speaker. This has it’s obvious benefits of being diverse as it can be used by both Apple products and other MP3 devices as well as the most unique feature of not requiring the music source to be physically connected to the dock to play music through it.

As using Bluetooth is the most attractive way to connect a music source to my speaker I must now consider how practical this method is in terms of the size, shape and other factors that may affect the effectiveness of this technology. First though, I must consider what components are necessary in process of having music play out loud from a music source out of a loud speaker. After some research I found out that the general process of sound from an audio device to a loud speaker goes : music source cable (auxiliary, Apple output, Bluetooth etc.) amplifier joining cable loud speaker

As I have identified the potential music source and the output source that would suit them, the next component I must develop is the amplifier. As these are reasonably standard the main priority is how all of these components will be displayed within my product. Here is some research I have done into this component. I have focused on how available it is, the cost and size of amplifiers.

Audio Device

The last component of my product I need to develop is the audio source and how it will be able to play music through my audio product. As I have already decided to use Apple products such as IPod's and IPhones as well as MP3 players the options for how to connect these music sources to my speaker are narrowed down.

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Another possibility would be to manufacture a separate dock where the audio source could be mounted and amplifier and any outputs could be hidden. Unlike the first option I am not limited by space as I would be able to manufacture the dock to the appropriate size.

Although I would prefer storing all the audio components directly onto the product and the music source onto the frame, the more practical option would be to manufacture a separate dock. In case during manufacture I find that I am unable to fit all of the components into the frame, the drawings demonstrate how I would construct a separate dock.

Although I am glad that I have developed and researched into alternative possibilities of how I would manufacture a docking port for an music source, I will still try and manufacture my most favourable choice of docking methods. This method would be to have all of the components such as the amplifier and Bluetooth device located within the frame of the speaker. Because I will have used Bluetooth there would be no need to cut a hole and construct a dock directly onto the metal frame, instead the user would simply be able to connect their music device directly to the speaker without an physical attachment.

My initial idea was to have the audio product mounted onto the front of the speaker as shown in the ProDesktop design. This would be the more effective idea in terms of the complexity of the product and how many wires and components are visible. The problem I have with this idea is the amount of space available within the metal frame where the amplifier and music source output would be located.

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DevelopmentThe aesthetics of my product is absolutely key, with the addition that many people will buy a product on the aesthetics along, which I discovered during my questionnaire. I stated in my questionnaire I would do further research into the design theme modernism, which I visually represented in my mood board. After comparing aspects of this design theme I believe it fits into my brief as well as the KEF product base, therefore I will bear in mind this design theme throughout the initial design process of my project. An additional piece of research where I focused on the aesthetics was brand profiling. Here I researched whether products are reflective to the brand in the profit and aesthetics; which I found the majority did. Because of this it is vital that I feature KEF’s sleek and high quality appearance that all of their products portray in my product.

During the part of my research called product profiling I discovered visually represented where I hoped my product would fit in the speaker market. I located my product in the higher end of the table which suggested my product would be modern and expensive. When looking at existing products that were also in the category many of them promoted the design theme modernism, which I will be featuring in the design of my product. This has convinced me that my product is at the correct pricing for the design and quality of materials I will be using.

Although I have specified my target audience as a well off, middle age market, there were some points that arose during the environmental snapshot part of my research that I need to address for a more general audience. I will be including a 3.5mm jack or an Apple specific jack so that users are able to plug their audio device into my speaker, such as an IPod or IPhone.

Despite my product having to be eye catching I also need the product to suit the environment that it will be displayed within. In my first-hand existing design analysis I discovered that many products didn’t need to stand out as the well known brand that had manufactured them would be enough for someone to buy the product. As mine won’t have this luxury the design has to be eye catching, however I am determined to stick to the design theme modernism and I also must bear in mine that the environment will most likely be a modern apparent, which when look at in my mood board consists of very neutral colours. Because of this I will have to use colours such as black, white and grey, however my product will be unique and eye catching through the shape and size of it instead.

Although safety features must be considered I am very unwilling to include any that may interfere with the aesthetics of the product. Because the design theme modernism includes a lot of straight, sharp corners and edges it seems unlikely that I will be rounding them off. However, as my target audience is of a mature age I would expect them to be aware of potential dangers such as the weight of my product as well as any sharp edges and corners.

As my product will be expensive in price the size will not be limited by prices of any potential materials. Additional I found in my environmental snapshot that other audio products weren’t being used as speakers, but more ornaments. Although the prime function of my product is to be able to play music, the look of my product must also be of a unique and high quality bearing in mine this information. Because of this I will design my product as a stand allow speaker so that it will be a more prominent feature within the environment it will be placed in.

I have specified throughout my research and within my brief that I would focus more on the aesthetics rather than the function. However, when I looked at my brand profiling I found that all products from each brand represented the brand and the values. Because of this I will include an innovative function, such as 360° sound, to improve the sound quality, however the technology will be one that KEF will already have used.

Despite wood not being a prominent material within the design theme modernism, it was the most popular material during my questionnaire. Although I will include it as a potential material in some initial designs it may have to change during the development process as it doesn’t suit the design theme modernism.

Development completedUnable/not willing to developNot yet addressed development

Like I stated in the previous checkpoint I have addressed the functionality of my product within the last section of my development. However, during the development I concluded that if it was possible I would try and use Bluetooth technology to connect the audio source to the speaker. Therefore there is no need for the 3.5mm auxiliary cable that I was intending on using.

360° sound was only a suggestion of a feature I could include within my product to make it more unique, however after deciding to include Bluetooth technology which I thought was a fairly original idea for audio products at least, I found there was no need to include this feature.