Anthony Henry

Medicine
reminding
With the

Aging
Population

Development

Content

Page

2 Ghant chart
3 introduction
4 6 PDS
7 9 reverse engineering
10 16 models
17 model overview
18 22 cad
23 25 material selection
26 manufacturing
27 30 technical
31 exploded
32 update on ghant

GHANT chart
Week 1
Week 2
Week 4
Week 5
Week 3
M T W T FM T W T FM T W T FM T W T FM T W T F

Tutorials/lessons

CAD
Reverse
engineering
Sketching features
Workshop
modeling
Functional model
Material research

Human factors
Testing
Aesthetic model

Project outline
The project should look to create a product which can be
always with the user when medication is due. The storage for the
medication should conform to approximately 32x22x30mm or a
similar size, avoiding the use of loud alarms. The medication
within the product must be attainable within 3 actions and hold
medication securely.

Product design specification

Function
1.1 The product must have a total storage volume of 21000mm3
1.2 - Any lights within the product must be visible during daylight
1.3 The product must securely clip to the user
Appearance
2.1 The warning light must be red to signify hazard
2.2 The product must be visually inviting and avoid technical and complex
displays
2.3 The material must be available in various colours to give a wide visual
range
Reliability + quality
3.1 The timer must be accurate according to the time the user has set
3.2 The clip must not break under constant usage
3.3 The lid must stay firmly on the product to protect the medicine
3.4 The user must be able to fit all their required medicine in the device.

Environment
4.1 Any lights used must be visible in 10000 lux
4.2 The clip should be attachable to various clothing to suit the time
and place.
Production cost
5.1 Production should cost between 7 - 30 (Class B product
marketable between 7- 30)
5.2 The plastic used in the design should be durable but also as cost
effective as possible.
5.3 High start up productions can be used if it provides a noticeable
difference in product performance in comparison to other methods.
Ergonomics
6.1 The timer shape should be cylindrical around 20mm for best grip to
the user
6.2 The lid for the pill storage should be easy release with a slide motion
or push to release mechanism.
6.3 All functional motions should be enforced with universal signals such as
arrows for a slide mechanism or textures for twist motions

Weight
7.1 The weight of the product must not effect the support of the clip
7.2 The product should look into being as light as possible with material
properties not being compromised
Process + quality
8.1 The process must suit the tolerances needed for the slide fit lid.
8.2 The quality of the final product should have an economic finish but not a
high end polish.
8.3 The final product material and manufacturing should offer a sturdy
product that offers good wear qualities.
Materials
9.1 The material selection should look into forms of plastic based on their
wear qualities and proficiency in manufacturing.
9.2 The LED lid should be a cloudy material to disguise the circuit board but
also display the light.

Any changes done to the specification must have justified testing and

Reverse engineering
Having reverse engineered an egg timer I
began to get an idea of what components I
wanted to keep in the design and what
needed to be removed.
The pivot arm was one thing in particular that
was unnecessary as my product specification
stated to stay away from alarms. Although This
particular model was priced at 1 it offered a
complex gear system which has been
produced for under 1.
By scaling down
the gears that
operate the timing
mechanism it has
no effect on the
angular distance
that the gears
rotate in a given
time.

The 3 sections
assembled consisting
of the timer, circuit
board and the
cover.
The top view shows the LEDs and the pins
that trigger the circuit board to use different
lights.

This view gives a clear view of the circuit

board which is fixed on top of the timer.

In addition to an egg timer I reverse

engineered a LED timer to better
understand how it worked. This product
was also featured in a model to display
how the LED timer could potentially
work as well.
The product featured The green light
being triggered upon activating the
timer followed by the metal pins on the
circuit board being triggered at 15
minutes from the finish to activate the
orange light and finally the red light
being activated in the same manor at
the end.
The timer component was the same as
the egg timer apart from with a larger
extruded pin leaving the top body of
the product to attach it to the casing.

Circuit board
Top

Bottom
P
3
0
P
3
2

P
3
1

P
3
4

P
4
0

The more
detailed version
of this can be
found on my
design for
manufacturing
poster.

After opening the LED timer I adjusted the circuit

board to remove the green on light the board to
create a new circuit board which triggers similarly at
15 minutes with the orange light and when the timer
is at 0 it produces a red light.

Model one
This model was created to test the lid mechanism and ensure a
smooth fit was given with the dimensions I used. This model was
printed small as I just wanted a quick display of how it could
work.

From this model I will carry forward the indents featured on the
lid for visual direction of use as well as the same style slide
mechanism.

Model two

Scaling this model up to create an idea of where everything should go

and how big the pill area and led could be was the main focus. Having
attempted to reduce space and go against my specification worked
well as there is still plenty of pill space and 10 pills are easily put in
there.

Testing the new size

Following the constraints of size in the
specification I wanted to test if the new size
would be effective for the average pill load in
a period of activeness for the elderly.
From my research the
highest pill dosage per
activity was at 8 so using
8 regular sized ibuprofen I
tested to see if they were
all able to fit within the
new dimensions.
Following this quick test I have came to the decision to allow the
reduction in pill space to give the design a more pocket size feel. In
realization that excess space in this pill box is unnecessary and will
create a more bulky final model. The space given allows easy access to
the pills and still air space between the lid and pills.

Model three
This model refines upon the form of model 2 and adds the led twisting as a
feature to display how it could work. One development to carry forward
from this model is the orientation of the clip. Rather than the Led facing the
user it is hidden so therefore in the next model it will be flipped.

Keeping the general dimensions I will create a final model with a variation
of color and other key features.

Although I could not find a torsion spring to fit I could still convey
how the clip would open and close as well as show useful features
such as the sliding lid. Having taken it home to show to potential
users with high medication they seemed to like the slide lid and felt
they had suitable medication space.

The directional arrow and

grips on the top lid also
offered clear instructions
on how to open or close
the product. The agreed
the timer was a useful,
nonintrusive method of
prompting them to take
medication.

Model four
The aim for this model was to use the LED timer to display
how it would work within my product. This scaled up
model clearly shows the LED in action. Although it is
effective I feel like the green light will not be needed in
the product, therefore it will be removed on the circuit for
the final manufacturing plans.

Model five
Finally this model displays the product in a
detailed manor with a finer finish.

Once the model came out of the 3d printer I

began to sand it down to produce a model which
is to a higher display standard. This model is the
only black one and is clearly the final looks like
prototype.

When the models are all lined up

you can really see the difference
between them and how theyve
developed throughout the stages
in small details. The final model as
shown in black will continue to be
refined by sanding and printing
the numbers on the LED section.

All of the 3d printed

models from the project.

Models overview
Features that will need to be
evaluated in manufacturing such
as draft angles and fillets will
tend to be on the minimal side to
not effect the design too much.
Also because of the size of the
design it shouldnt particularly
suffer from manufacturing
restrictions.

Cad models
With these renders you can clearly see
the pill storage and where the lid slides
on to the product. The smooth fit is
secure for the user and easy to get on
and off.

Building the parts up to create a final image on

solidworks of the product with the red led on shows
where the spring slots into and the orientation of the
clip clearly.

After the user has set the time

for their medication the device
will use the following lights for
each time.

.15.30.45

0.15.30

1200.15

Variation in colour
.15.30..

.15.30..

.15.30..

Because of the nature of the product it

allows various colours to be applied. This
variety allows the user to select which
colour they would be most likely to use or
what would go best with what they're
wearing if they have multiple products.

Initially skeptical about the brighter

variations in colour they began to warm
on me and remind me of the newer
iPhones with colour. Although limited by
these colours in solidworks, there would
be no limitation come manufacturing
and a wider range would be available.

.15.30.45

.15.30.45

.15.30.45

Using a quick
solidworks render
with this scenario
gives a good
visual context to
the product.

The pill box will give a clear visual

stimulus particularly when seated as
the led will be in direct line with the
user.

Polymers Thermoplastics
High
High
tensile manufacturing
strength accuracy
Durable Suitable
Acrylonitrile-butadiene-styrene (ABS
Cellulose acetate polymers (CA)
Ionomers
Polyamides (Nylons, PA
Polycarbonate (PC)
Polyetheretherketone (PEEK)
Polyethylene (PE, HDPE, LDPE)
Polyethylene terephthalate (PET)
Polymethyl methacrylate (Acrylic, PMMA)
Polyoxymethylene (Acetal, POM).
Polypropylene (PP)
Polystyrene (PS)
Polytetrafluoroethylene (Teflon, PTFE).
Polyurethane (tpPUR)
Polyvinylchloride (tpPVC)

y
y
y
y
y
y
y
N
y
N
N

y
y
y
y
y
y
y
y
y
y
y

y
y
y
y
y
y
y
y
N
y
N
N

y
y
y
y
y
y
y
y
y
y

Polymers elastomers and thermosets

High
High
tensile manufacturing
strength accuracy
Durable Suitable
Alkyds / Polyester
Amino (Urea / Melamine)
Epoxy
Phenolics
Polyimides
Polyurethane
Silicone
Nonoil-resistant rubbers
Oil-resistant rubbers
Thermoplastic elastomers

y
y
y
N
y
y
y
y
y
y

y
y
N
N
N
y
y
y
y
y

y
y
Y
Y
N
y
y
y
y
y

N
y
N
N
N
y
N
N
N
N

Material with filler

Following further reading and research from books
such as material for design I selected the material
down to Pollyproperlyne. In addition I began looking
on CES edupack to further explore fillers.

After carefully assessing the many fillers I decided

that the carbon filled one was best suited because it
offered the best wear. Further costing and material
qualities can be found on the manufacturing poster.

Manufacturing
Using reading material for my manufacturing process I
came to the conclusion that injection molding with a
retractable core would be the most cost effective
method to create each section. This allows me to
produce the parts in one process without having to
cut in the specific indents needed in the lid and body.
The tolerance for injection molding is very accurate
and it also offers little waste. The start up cost is high
however producing 100,000 units would make up for
this and allow the positive high accuracy to be
applied to the product at relatively low prices.

With the technical drawings the hardest dimensions to show

were the indents and the triangle at the top. In the notes I
made sure to specify the triangle was an equilateral and not
leave it down to assumption with the other 2 sides.

Of the 3 drawings this was the simplest because of the

simplicity. Making sure the technical drawing had all of the
required sections such as the spring hole and any other
extruded cuts.

Similarly to the body of the pill container I ensured all indents

had detailed views giving a more refined tolerance in this
section as the fit needed to be as close as possible to the
original designs.

Design for manufacture

The majority of the design for manufacture information
can be found on my poster however as a summary
the draft angle is at 0.25 degrees, fillets are 1.5mm
on the bulk of the design to give a smoother plastic
flow as well as a few 0.5 and 1 mm fillets specified on
the technical drawings. With the material and
manufacturing process the tolerance ranges between
0.06 and 0.1. the lowest possible tolerance was
required for the slide fit sections.

GHANT chart Update

Week 1
Week 2
Week 4
Week 5
Week 3
M T W T FM T W T FM T W T FM T W T FM T W T F

Tutorials/lessons
CAD
Reverse
engineering
Sketching features
Workshop
modeling
Functional model
Material research
Human factors
Testing
Aesthetic model
Re-designing concept