PRODUCT DESIGN

SAM WILD 3166

TASK ANALYSIS
Scenario: A mail order
company wishes to offer a
range of products based
upon 20th century design
movements.
You
are
required to choose one such
movement and to design and
make a product or range of
products which reflect the
essential features of the
movement. You will need to
investigate a specific target
market.
Brief: I am going to design
and build a battery powered,
personal desk fan in the
Steampunk/Retro-futuristic
style. The product will be
small but powerful, running
off a 9 volt battery, and will
be sturdy and well built whilst
staying cheap and cost
effective.

Who?

This product is aimed at any person who wants a fan that is more interesting than a cheap store
bought one whilst retaining the function of a popular mass produced product. My personal client
is going to be a family member who I can work with on a regular basis to ensure the design suits
their needs and style recommendations to the best of my ability.

What?

I chose to build in the Steampunk style as my client is a fan of vintage items and also modern
and future technological advancements. The product will be a small and powerful desk fan which
is not too space intrusive but still serves a useful purpose and is fairly powerful whilst being
powered by a battery.

Why?

Nearly all commercially available fans nowadays are either too large or very poorly produced to
be used reliably and regularly without spending a large sum or money. My product will be
available for a comparatively cheap price for the quality and reliability I aim to achieve.
After a brief conversation with my client, I decided a smaller fan for a desk would be of more use
to him than a large one as he will be taking it to work and using it there. He works in a busy office
where his working location within the building changes regularly so a small product is easier to
store in a locker to then take out and use the next day.

Where?

As my product is originally intended for use on a desk, it will be small and therefore versatile in
location. It will be light and therefore easy to carry around a house or an office if you are moving
workstation. As it will be battery powered it will be able to be used theoretically anywhere.

DESIGN SPECIFICATION
Design Specification
My product..
Aesthetics

..will fit the retro-futuristic style.

..wont copy an existing product but clearly shows inspiration from other products and ideas of the movement.
..must be attractive and eye catching without detracting from the function.

Cost

..will not cost more than my clients budget & I will use school tools and machinery with care so not to break saw blades etc.

Customer / Target Market

..will suit all the needs of my client.

..must make the customer happy so they dont sell it back.
..will be aimed at people with high quality taste who need a fan.

Environment

..must be simple to move small distances and strong enough to not break when knocked or nudged.
..must fit in a relatively small space on a approx. 3m square desk.

Safety

..must not have exposed live wires with no insulation with high current flowing, this should be easy as it will be battery powered.
..will have all joints and fixings tested to ensure they dont come apart or come loose at any point in the foreseeable future.

Size

..must fit on a relatively small desk so should be no larger than 300 x 300 x 200mm
..must not be overly heavy so it can be moved with relative ease.

Function

..will have spinning blades to create an artificial breeze to gently cool the user.
..must look good even when not in use so it can be left out as an ornament as much as it is a useable appliance.

Materials

..will use shiny hard woods and curved veneers to match the style more.
..will utilise modern processes like 3D printing and laser cutting to give perfectly finished parts.

Sustainability

..will be made with new materialsas well as wood and metal which can be recylced or disposed of safely.
..will not waste materials in the manufacturing process.

RESEARCH PLAN
Research is essential to the design and development process of making anything, and especially so as this will be a one off product it
needs to be of excellent quality. Researching into the design movement and existing products will open my mind to more ideas and
give me more features to incorporate in my designs. Different areas of research will give me useful information to help develop my
ideas into a well crafted product which fits all my clients needs and wants.

MATERIAL RESEARCH
NAME

PHOTO

DESCRIPTION

How I could use it

MDF

Medium density fibreboard is a

manufactured board that is fairly
strong when thick.

Any component which doesnt have to be super

strong, or is fairly thick. MDF can be cut into
almost any shape but it isnt the prettiest of woods.

Oak

Light brown colour, strong, hard,

tough, open-grained, corrodes steel
screws and fittings.

Base pieces/stands and components which will be

finished with varnish to shine. This will be used
frequently in my final design as it can be stained
dark and polished to a shine.

Chipboard

Strong and very cheap wood, often

veneered with plastic or a thin
hardwood.

I can use this to make a former for a veneered part

or curve, or for use on the vacuum former. I will
use this for a curve going over the back pillar on
my final design.

Mild Steel

Made with less than 2% carbon,

magnetic, not that brittle. Silver but
doesn't shine much.

Comes in tubes, sheets and bars, this would be

useful for small metal parts as it can be bent in
thin quantities. It can be bent so I will use it to
make clamps or pieces to hold down other
components.

Aluminium

Very versatile, lightweight and

strong. Comes in many stock forms
and shines silver with a bit of

I could turn parts on the lathe, or use sheets for

larger coverage. It's really versatile so I could use
it for almost any type of component. This will be

STEAMPUNK INSPIRATION PAGE

Retro-futurism is a movement that shows the

future in an earlier era. Often incredible flying
machines such as airships or flying trains
generally powered by steam (hence Steampunk).

Retro-futurism was first seen in the 1960s, as

this time was full of technological revolution and
the general thought that life would inevitably
improve though technology.

Inspired various media such as Star Wars and

some pop art pieces.

Features of Retro futurism

Mechanical
Pipes
Organised but asymmetric
Metallic
Propellers
Gauges
Steam outlets
Flying vehicles
Airships/Zeppelins
Cogs/Gears
Intricate detail
Silver/Gold/Bronze
Dull shines
Chains
Leather/Linen
Metals
Open bulbs
Wires
Bolts/Visible Rivets

CLIENT PROFILE
Who? - My client is a 46 year old male who works on a computer in an office environmenor
at home on a laptop.
Why? - I am making this product as his office has very little decoration and is often stuffy
due to low quality ventilation and large amounts of people in moderately sized rooms.
During the winter the few windows (which dont open much steam up, my product will start
to reduce this, or at least make the area closer to him less stuffy as the air would be moving
around more.
Interests - My client likes interesting looking objects and is a fan of vintage items such as
record players and candlestick holders, he dislikes dull looking items so the steampunk
theme will be enormously better than a simple or plain design style.
He doesnt have any fans or other cooling devices at his office so my product will fill this
gap.
Environment - His office is bare and plain with white walls, a plastic veneered desk and a
plaster ceiling, a desk fan of this style will make the environment much more interesting and
pleasing to see. His desk has space for his laptop, laptop stand, second screen, keyboard,
mouse and various cups of tea. If I make the product too big it will take up too much space
on his desk, which wouldnt help, so I need to make sure I restrict the overall dimensions of
the fan are large enough to produce a suitable but not so large that they intrude on desk
space.

PRODUCT ANALYSIS 1 & 2

Aesthetics - This fan has a shiny chrome finish all over. This provides a new, flashy and stylish look which
would fit into most environments and be eye-pleasing.
Cost - The cost is 34.99. This reflects the all metal finish and the high quality look of the product.
Customer - Anyone who has a room that needs cooling down, it isnt too expensive so it almost anyone
could afford it but there are much nicer looking fans on the market.
Environment - This product could be used in a bedroom or an office, on a shelf or desk. It could possibly be
used on the floor but the customer would have to be careful around it.
Size - Height: 430mm, Weight 340mm, Depth 250mm. The product is a practical size for function and its
large diameter means it will cool a room down quickly.
Safety - The cable could be a trip hazard if not run safely to a plug. The metal may be sharp on the base
plate. If the grate was not fitted correctly the blades could cause damage to limbs. If the electrics get wet
there would be a risk of electrocution.
Function - Air is pushed by rotating blades to cool a room down. The top section oscillates about 150
horizontally and can be tilted up and down a small amount. It has 3 different speeds, and stopped, which are
controlled by a knob on the back.
Manufacture - The base plate looks to have been made from a mould as it is very smooth and accurate, this
would also be efficient on a production line. Most parts are two components held together, such as the pillar,
the grate is a mesh of sturdy wires. I imagine it was assembled on a production line as it came in a box fully
made.
Material - The fan is almost entirely metal, besides the controls on the back and some of the electronic parts
inside.
Sustainability - The metal and plastic could be melted down and formed into something else. Plastics aren't
very biodegradable so they would be just wasting landfill space if not disposed of correctly.
Comments - This product is a fairly large and expensive desk/room fan from Argos, its made by Challenge
who sell through Argos, Amazon and other sellers. It doesnt fit my design movement but is still useful in
learning what sort of other products are out there. I think the all-silver finish looks of high quality but could
become annoying if the lights in the room are bright as it will reflect light around the room. I agree with the
pricing though, as it is 12 inches in diameter it is a large product and this is a competitive price.

Aesthetics - The product has a wooden base, soft shiny gold blades, a black guard around the blades, a
gold tube going from the base to the pillar which I assume is just for looks. The motor is visible and on
the wooden base. I really like the chain driven idea, and I may use this in my design or some variant of it.
The bottom of the pillar is an intricate work of metal which is painted black and looks really good, it fits
the steampunk style very well and compliments the gold feet on the base of the wooden box.
Cost - I
do not know the cost of this product as it is a unique model and made of parts which look recycled from
other products or uses. I would estimate that this is worth around 60 as it is of very high quality and is
clearly strongly made.
Customer - People who have excellent taste in household appliances would buy this, Or those who want
a really incredible unique fan. Its quite a classy product and is more for looks than function.
Environment - This product could be used in a bedroom or an office, on a shelf or desk. It could possibly
be used on the floor but the customer would have to be careful around it. This product is built for looks so
it would probably be in pride of place on a table or shelf.
Size - Approximately 500mm x 300mm x 250mm.
Safety - The blades are protected by a wire guard, this will deter anyone from putting their fingers in it but
it does cover most of it. I imagine it is fairly heavy so it shouldn't be left precariously on shelves or high
places.
Function - The motor turns a gear which spins a chain which spins the fan blades, this is a very original
idea and I may adapt some of my designs to add some more visual looks.
Manufacture - The base is made of 5 pieces of wood making a cuboid with no base, this leaves space
for the control switch. The base of the pillar has been cast out of a soft metal then painted black. The
pillar looks like a brass pipe of some kind which may have used to be part of something else. The fan
blades look like they have been made of sheet metal and bent slightly. The wire frame has probably been
bent around a template and welded together.
Sustainability - This product can almost be fully recycled as it is only made of metal and wood. The
motor can't be as it is electrical and the wires would have to be taken out.
Material - The base is a hard wood, could be walnut or cedar, which looks like it has a polyurethane
finish on as it is especially shiny, the feet look like they may be cast aluminium, the blades are most likely
brass which has been curved and polished, the pillars look like copper pipe with a gold or brass coating,
the frame could be any malleable metal painted black, quite possibly steel in this case, and the intricate
base of the pillar is cast iron.
Comments - This fan, in my opinion, is really high quality and is a product I would be proud of making. It
was made as a one of product and there is a set of guides on Instructables about how to make
something similar to it. I really like the chain driven idea and I will certainly use this as inspiration for my
product as it really helps the steampunk style and looks very unique.

PRODUCT ANALYSIS 3 & PRODUCT DISASSEMBLY

Aesthetics - This is a very simply design product. It is one colour and one main material. The
body is small and circular with a plastic mesh covering the soft fan blades. The base frame is
glossy black plastic which makes the product very light but still sturdy.
Cost - This product costs 3.14 from Amazon. This is reflected in the size of the product and the
material quality.
Customer - As this is powered from a USB cable this product is probably aimed those who work
on computers a lot, or are mobile with laptops. The cost means almost anyone could get it and is
not made to cool entire warehouses. It is a fan for one person to use.
Environment - This will be used in an office or generally near a computer.
Safety - The blades are almost inaccessible and are made of a soft material so they shouldn't
hurt any body parts. It is a very light product so it won't hurt any being if it fell on them from a
high place. All the edges are soft and rounded.
Size - The dimensions are: 149.73 x 96.3 x 146.5 mm.
The diameter of the fan blades (in total) is 96mm. It weighs 190 grams.
Function - The USB cable is plugged into a computer or laptop and the blades spin at high
speed. The main section of the product tilts back and forth on a simple pivot.
Material - The entire product is made of plastic (besides the motor, wires and USB plug) which
makes it cheap to mass produce. The black finish provides a sleek yet depressingly cheap look,
and would not stand out in any room.
Sustainability - The USB cable could be cut off and reused and the plastic parts can be
recycled but the motor and wires would have to be disposed of properly.
Manufacture - I think most of the product was made using injection moulding and then glued
together, the pivot points are plastic too.
Comments This is a very cheap, yet moderately well made fan. It is lightweight so it can move
around easily and can tilt up and down, which is useful I plan to make a product that isnt
designed to move around a lot, but it isnt inconvenient to do so.

Aesthetics - This extractor fan is plain and white, made exclusively of white injection moulded plastic
apart from the motor and PCB. It would be mostly out of sight during its use so it doesnt need to be
particularly attractive. The fan has seven blades and is very sturdy as it the entire shell and case, the
plastic is fairly thick and would easily last in constant use.
Cost - As this was given to me by a teacher, I dont know exactly what the price was but similar
products cost between 20 to 50 depending on size and quality.
Customer - This is a sturdy but probably fairly cheap fan so it could be used in any bathroom in the
home, I imagine it wouldnt suffice for larger scale shower rooms, for instance at a gym, as it is fairly
small.
Environment - The fan is designed for use in a bathroom with a shower, as it is plain it will fit in with
most colour schemes and wont draw attention.
Safety - The product would be high up in the room so wouldnt pose an issue for getting your fingers
stuck, however if you do put your fingers in, it wont cut you as the blades have dull edges although it
might still hurt. I never saw the fan in action but as it isnt meant to create a strong airflow the fan speed
wasnt likely that high.
Size - Approximate Dimensions: 200 x 190 x 140mm, the product doesnt need to be large and with the
PCB tucked out of the way it is very compact.
Function - The product is plugged in via the electronics in the house, and pulls air out of the room it is
located in, this keeps the air in the room clear and, in the case of bathrooms, removes excess humidity
by pulling less humid air in from other rooms.
Material - The shell is injection moulded plastic (I can see visible join marks), as it the PCB case and
fan blades. The motor is standard and the PCB is just a normal circuit board.
Sustainability - I do not think this product can be recycled, it can be disposed of at refuse centres in
the appliances section.
Manufacture - All plastic parts are injection moulded for cheapness and efficiency and the motor
and PCB are industrially made on a large scale, as these are fairly standard parts.
Comments This would be a fairly useful addition to most bathrooms, it was interesting to take apart
and see just how simple it is inside: A motor and a PCB are the only electrical components. When I test
different blade shapes I will consider a wide centred one with a lot of depth for my design to match this
product.

QUESTIONAIRE
Design
Q: What do you like about the Steampunk movement?
A: It's cool, I like the concept of having a machine that works as well as a modern device but looks like it was designed and made
in the victorian/industrial era. I like the visible cogs and chains.
Q: What materials and finishes suit this movement well?
A: Iron, polished woods, leather, any natural materials. Dark, polished and shiny, but rough and rustic.
Q: Are there any ideas which you dislike from the Steampunk movement?
A: Not really.
Environment
Q: Where would you use this product?
A: At work, in my office which is shared with several others and often becomes stuffy in the colder months when the heating is on
(its old and crap)
Q: Why do you need/want this product?
A: It will create a small talking point in the office, and will keep the stuffy air out my face during winter.
Q: What size restrictions will this product have to adhere to?
A: It needs to be small to fit on my desk, work recently downgraded everyone space.
Cost
Q: Do you currently have a desk fan? If so how expensive was it and how well does it work?
A: Yes, I have a fan which I bought over 4 years ago for 25, it is terrible now but I don't have the heart to get rid of it so a new
flashy fan which actually works will replace it in my heart and on my desk.
Q: How much is the most you would spend on a high quality Steampunk fan?
A: About thirty quid
Safety
Q: Do you think you will need any safety restrictons?
A: As long as it isn't too big, it wont need to have any blade protection as I'm the only one who will be near it

RESEACH CONCLUSIONS
Inspiration Page My inspiration page will be invaluable during the design process as it is a summary of the entire design
movement in one page. The list of key features will give me ideas of parts to add to my designs as I go and the photos will show me
similar products and themes that I need to stay similar to. Overall, the inspiration page will be a very useful addition to my research
and I have learnt many key features of steampunk that I will need to add to my designs.

Client Profile Creating a page of my clients interests, hobbies and the environment the product will be used in will be really
useful. I have found out what environment the product will be used in which will give me a much better idea of what to make it look
like as I will know how to make it fit in with his office whilst still drawing attention and interest whilst still serving a function.

Material/Finish Research This gave me a better insight to what the components of my product are made of, instead of just
refering to materials as wood or metal I can give specific names of type of that material and explain why they are the best for the
job I want them to do.

Client Questionaire - These answers will be very useful to me in different stages of design and planning. His material suggestion
will be incredibly valuable throughout the design and improvement stage as I always need to think about what my client wants. The
ideas and suggestions he gave will be something I need to consider each time I put pencil to paper in the design process, and when I
develop those ideas and take them further into a final design.

Product Analysis These were useful to do as they will give me a better sense of what else is available on the market (or what
other similar products have been produced in this style). I found out that steampunk fans when made well look truly wonderful,
something I wish to replicate in my product. Each of the products had pros and cons, and I can use what I've learnt to not make the
mistakes that they did and make sure mine is super smart and well finished.

DESIGN DEVELOPMENT

Design Ideas 1
Aesthetic This product is based around a control panel and a windmill; with some
adaptions. The base is small, rectangular and sloped towards the user, it has a
control-panel-esque fader/slider on the left and an ammeter style gauge on the right
which will show fan speed by voltage from the circuit.
Customer This product is aimed at vintage and steampunk enthusiasts. The
design is fancy but the function is still there so the look doesnt overshadow the use
too much.
Cost If this was completed to a high quality, it would sell for between 40 to 60 as
a special, custom made, one off product for a certain client.
Environment The product would fit in with a vintage/old fashioned house style or
even as a standalone piece, to add sophistication to the room. It is not a large product
so it would fit on nearly all desks and shelves or even on the floor.
Safety The main issue of this product is the exposed fan blades. It does have a
simple blade surrounding in the form of metal rods which are bent into shape. As this
is powered by a phone charger style plug, it doesnt run off high voltages and all the
wires are hidden, so as long as it isnt disassembled or soaked: the product is
electrically safe.
Size 400 x 250 x 150mm, fairly large but is useful for its size.
Function The fader at the bottom works as a variable resistor which will control the
fan speed, the dial will simply show the current of the circuit using an ammeter which
is taken apart and incorparated into the base. The fan blades will spin and the air
around it will be pushed away from the product, creating a steady airflow to simulate
wind on the user.
Manufacture The base is made of six pieces of oak wood, they are held together by
finger joints and will be polished up to a very smooth finish. There is a hole drilled in
the centre of the upper panel, which the pillar fits into and is screwed to the bottom.
The back of the pillar will have a channel routered into it to keep the wires tidy and not
visible, this is more possible than drilling the entire way through the pillar. The motor is
secured by a clamp made of a piece of mild steel plate, cut to size and screwed into
the top of the pillar which itself is made of a block of oak which polished to match the
base. The wire frame is a thin metal rod which has been bent round a jig made of
laser cut plywood and is held on with two more rods going through the pillar top.
Sustainability All wooden and metal parts can be recylced and the electronic
components can be disposed of with appliances at a refuse centre.
Material The base and pillar top are oak, the pillar is a dowel, the
Notes/Opinions As a first deisgn I think this is a good attempt. The idea of being
able to control fan speed is a good idea, and the general design is good. I'm not sure
about blade gaurds, this one looks good as its minimal. I also need to decide on power
source, the phone charger idea is good as it wont need replacing, but batteries are
good for portability.

Design Ideas 2
Aesthetic This design is based on a wind turbine, it has large exposed blades and
a large, sturdy, octagonal, base which acts as a floor. The pillar is solid, lathe turned,
walnut and the motor is clamped on the top with a handmade metal clamp. The base
is shiny on the top and side faces and the pillar is given a weathered look with
darker varnish in places and some gentle burns. There is a dial to control the fan
speed, a dial is more style fitting than buttons like on most fans.
Customer This product is aimed at vintage and steampunk enthusiasts. The
design is fancy but the function is still there so the look doesnt overshadow the use
too much.
Cost This is an easier build than the previous one, so I would say it would sell for
30 to 40.
Environment This could be used on a shelf or a table at home as it is quite large,
it would need to be in a place where it wont hit anything as the blades are long.
Safety There is no blade guard so it would need to be turned off/put out of range
of small children, it could hit them and as it is a fast moving, large object it would
certainly hurt. There is no risk of electrocution as the wires on the back of the motor
would be insulated.
Size 500 x 400 x 300 (Each blade is 150mm). Large blades will give more airflow
as they have a larger surface area to push with.
Function The dial on the front acts a variable resistor and controls the fan speed,
the fan blades spin at a high speed and push air through the area its in. I will need a
high powered motor as the blades are fairly heavy.
Manufacture The base is made of 10 parts, each side will be hand cut and

made of pine or a similar coloured wood, the bottom and top will be laser cut
and varnished to match the colour of the sides. The pillar will be turned on a
lathe and will have a hole drilled through it all for the wires for the motor to go
into the base where the electronics will be hidden. The blades are either going to
be cut from two layers of 3mm plywood and then joined to create a better shape for
pushing air, or will be laser cut out of acrylic and then heated and twisted to shape.
The dial will be 3D printed out of ABS or PLA then gently sanded until its very
smooth.
Sustainability All the wooden parts are recyclable and the electic components
can be disposed of safely. I can buy parts from places that are eco friendly so I
remain as undestructive as possible.
Notes/Opinions I think this design is too simple. It doesn't include enough
processes in the manufacturing, and is almost entirely wooden. I like the lack of
blade guard as it fits the style better and the large blades make the windmill idea
really stand out.

Design Ideas 3
Aesthetic This design is a much more developed idea from the last, it has an 'n' shpaed base
with a central oak pillar and two copper pipes to act as supports. The motor is on the top of the
pillar and the wires run down the back of the pillar. The copper piping will be given a weathered
effect, with scratches and dirty marks on. This will emphasise the steampunk style along with the
blade shape. As you can see, I came up with several ideas which when painted will suit the
style very well. The base would be made of a dark wood, maybe stained walnut or even painted
pine.
Customer This product is aimed at vintage and steampunk enthusiasts. The design is fancy
but the function is still there so the look doesnt overshadow the use too much.
Cost This is made of simple parts, so wouldnt come to more than around 25 for parts and
could be sold for up to 40. The most expensive part would be the filament for the 3D printer if I
was to use the wood/pla combination filament I plan to. This comes to about 25 depending on
the supplier.
Environment As this is a fan, it will be used on a desk or a shelf or a table. But as this is a very
interesting looking fan it could be used simply as a piece of furniture and decoration.
Safety This design would not have a blade guard to fit the style better, but if my client asked for
one I could use a similar idea to my previous designs: use a template to bend thin rods of metal
into a simple grate.
Size Approx. 350 x 400 x 250mm with each blade measuring 150mm long
Function The speed of the motor is controlled by buttons or a dial on the middle section of the
base, this makes the motor turn and pushes air around the room. This product would be able to
be used by anyone over the age of 4 or 5 as it has fast moving parts.
Manufacture The base would be cut on a band saw or with a tenon saw to make all the cuts
straight and accurate. The base is held together with large finger/comb joints, and the underside
of the base has an area routered or drilled out of it to give room for the dial/button electronics.
The copper pipes will be cut to length with a hacksaw and they will be joined with 135 degree
joints that you can buy from hardware stores or online. I will drill holes into the pillar and the base
to help the pipes stay in place and use epoxy resin or hot glue to secure them. The pillar will be
turned down on a lathe, and the blades and blade holder will be 3D printed; the blades will be
made of a PLA/wood hybrid filament for very nice looks as well as the strength of PLA. The base
will be finished wil varnish and sanded smooth, the pipes will be polished and given a weathered
look with some light spray paint to give it a nice effect.
Sustainability As far as possible I would use materials from sources that are being sustainable
and responsible with their sourcing methods. This can be mostly recycled as it is wood and
metal, the plastic would be binned safely and the electronics would be taken to a proper disposal
centre.
Notes/Opinions This design has several good features: it incorparates more metal parts which
fits the steampunk style a lot better. The fan blade designs I came up with at the time of
designing this are more intracate than previous designs which would only be possible to make
with either a lot of time or a 3D printer. Overall I like this design and will more than likely use parts
of the design in my final design.

Design Ideas 4
Aesthetic This design is minimal and doesn't include that many obvious steampunk
features. The base is minimal but a good shape, the hexagonal shape suits the style as it
is irregular and peculiar looking. The pillar is too simple and needs to be modified to make
it more interesting and less blocky. However, the main development of this design is
having the motor at the botton instead of the top, an idea which I got from one of my
product analysis'. This idea is a really good concept and it really really makes the style
show so much more than if it was at the top. In this design the chain was on the back of
the unit, with an axel at the top and the bottom of the pillar.
Customer As the design is pretty simple it would fit in with most households so almost
anyone could purchase it. It is aimed at vintage lovers and anyone who is willing to pay for
a more developed and not mass produced fan.
Cost It is more simple than some other designs so would be cheaper to manufacture
and would sell for less.
Environment The product could be used almost anywhere as long as it had a power
supply.
Safety The product has a large base and a central centre of mass, so it would be
unlikely to fall over when in use. There is once again no blade guard as it suits the style
better.
Size This could be large or small but would make most sense as a personal desk fan.
EG: 250 x 300 x 400mm
Function This design is simply an on/off design, for simplicity and because it wouldn't
need to be complicated if its just a small desk fan. The motor spins an axel at the base of
the pillar, which drives a chain on a gear which in turn spins the fan blades on another
axel with a smaller gear at the top of the pillar.
Manufacture The base is a solid dark hardwood which is joined to the bottom of the
pillar by a bolt. The pillar could be pine or walnut. The fan blades will be laser cut acrylic
and the motor will be housed in the botton of the pillar, with the wires coming towards the
user and going into a hole just behind it, which go underneath to the power cable going
out the back. Each axel is an aluminium rod which may have extra features (such as a
cap at one end) turned into it on a lathe.
Notes/Opinions I will take a lot from this design, I need to incorparate enough
steampunk features into each and also use the idea of a lower motor as it not only looks
good but will also add a level of complexity to my overall design. I would add more to the
front of the base though as it is rather bare, controls or just an extra feature or two.

MODELS
Where this idea came from: This design is an amalgamation of several features from several designs. The 'arms' come from sketch 3 and (if they were round)
would look very good as they suit the steampunk style well and the use of copper pipes adds an extra part to the manufacturing process. The base is also based
off sketch 3 as it has the two front 'legs' that stick out, this turned out to not work out very well however. The pillar is an idea that is in all of my sketches, and
almost any of the pillars from any of the sketches would work in this design and would look good too.
Good parts:
The white paper pieces 'supporting' the pillar represent the above mentioned copper pipes, these will match the style well and will give it a more industrial look.
The red dot on the lower left represents a variable resistor that would control the speed of the fan, this is a feature that I think really fits with the movement,
especially if I 3D print a valve wheel style part to go over it, and paint it red to look like a pipe valve.

Bad parts:
The base shape was badly thought out, it was too short out to the front which made it unstable and unable to support the pillar and where the motor will be.
This is a very blocky model, which would change if it was the final piece but I will need to remember that my final design shouldn't have lots of straight edges,
but should be mixed with curves and edges to look best.

Where this idea came from: This model is a developed version of the one above: and incorparates some new ideas from the sketches I have done
already. This fan is belt driven in the actual product the belt wouldn't be as wide and a much larger base size. The blades also have a much nicer
shape, which suit the style a lot more.
Good parts:
The base shape is a lot more stable than the one above, it comes further forward to support the upper axel and the fan blades.
The belt is a really good addition, which comes from sketch 4 but the belt isnt internal like that one, it is outside and exposed, which adds to the
style a lot more than the non visible belt or a motor right by the fan blades.
Bad parts: The back pillar is really very basic, but this can be adapted in further designs and thoughts, although a blocky design would look bad on
the outside, there is a lot that would need to be drilled/routed into the pillar to incorparate the motor at the bottom and the axel at the top.
The axel on this model is way too large to be realistic for the final piece, however if it was thinned out a lot it would work well.

TEST PIECES
I made a test piece of a three tooth finger
joint, this was to test my skill and
accuracy with hand tools, as I made
this before I had gained in confidence
with woodworking it could be a lot
better but I was proud of the fact that it
fit together at all. If I was to do it again
I would take more time over using the
chisel to remove the excess wood as
this trial has some innacuracies due to
messiness and also rushing work
something I will remember not to do
during my final manufacturing process.

FINAL DESIGN SKETCHES AND PLANNING

I came up with an idea I
liked, which included
several steampunk themes
and ideas from my initial
ideas. The main ones are
the belt driven fans with the
motor at the bottom of the
pillar, the exposed wires
from the motor, the dark
woods and the copper
coloured blades.

The idea started with a box

around the motor but I
changed it to no box, just a
stand to leave the wires
exposed and open to make
it look more industrial and
technological.

Above: This is an innacurate sketch of

the product from the back with no pillar
in place, this has an older base design.
I think these fan blades look very
good.
Top Right: A quick sketch of the
almost final design, it has a base
shape that is simple yet effective and
very good looking as the polished dark
wood will bring out the style very well.
Right: A sketch of the top of the pillar
and the axel and bearings. The axel
will be turned down from a 10mm rod
so I can have a cap on one end and a
thin part to go into the blade holder.

Final Design: CAD

PARTS
Veneered pillar
Lathe turned axel
Laser-cut front and back pieces
Oak base and stands
3D printed gears
Painted acrylic blades
3D printed blade holder
Pine pillar
Mild steel motor clamp

RENDERED CAD

PRODUCTION
PLAN PAGE 1
Making of the veneered
curve and the base

PRODUCTION
PLAN PAGE 2
Making of the motor stand,
the axel and the pillar

MANUFACTURE DIARY (1)

Making the veneered curve. I started with 4 pieces of
chipboard and my laser cut template. I drew around the
template and used the holes to mark the locations of
where I will drill. I used a tenon saw to roughly cut out
the shape from the rectangles and then a coping saw to
cut it almost down to the lines. I then drilled the holes,
cut the threaded rod to length and bolted it all together
(including the template). This made it easy for me to use
the belt sander to get the curve smooth, accurate and
perpendicular the the flat sides. Once I had hand sanded
the former up to 240 grit to ensure its perfectly smooth I
trimmed the threaded rods down so they only just stuck
out from the bolts this was to make sure the vacuum
bag doesnt rip on the sharp edges. I cut the veneers out
using a craft knife and a steel ruler (being careful to
keep my fingers out the way of the path of the knife).
Using a paintbrush I covered the appropriate sides of the
veneers with a layer of glue and stuck them all together
to each other and not the former. The vacuum was then
turned on and left running for around 30 minutes for the
glue to start drying. I then removed the work from the
bag and put it in a woodworking vice with scrap wood
either side (for protection) to leave over night to fully dry.

MANUFACTURE DIARY (2)

To make the axel, I used the centre lathe. I began with an 18mm
aluminium rod and fine marker pen, I marked 10mm, 50mm and
55mm from the end. I then clamped the rod in the lathe and
turned it on. I used a cutting tool to turn down the rod in the first
section to 5mm diameter which I checked with digital calipers
to ensure accuracy. I repeated this process for the other two
sections and then used a parting tool to cut off the almost
complete axel. To finish the axel, I used a hacksaw to cut off the
extra piece (photo in the middle left) then a file to smooth the cut
down to a flat surface.
The blades and blade holder were designed and manufactured using
3D and 2D modeling in Autodesk and Techsoft 2D Design. The
blade holder was first 3D printed in one piece but because of the
aestetics I wanted on one side and the hole that needed to be on
the other, it was only possible if it was printed in two pieces
which were then glued together using 2 part epoxy. After printing
there was a lot of extra material so I had to carefully remove it
with a chisel, I put it gently in a vice so I didnt accidently chisel
my hands or fingers The blades were simply laser cut and then
glued into the perfectly fitting holes in the blade holder. The level
of accuracy that was needed to make the pieces fit and looks so
good would only be possible with CAD and machine
manufacture.

MANUFACTURE DIARY (3)

For the base I started with a piece of oak, there were
some imperfections on one side so I decided to
make this the side that wouldn't be visible the
underside. I used a ruler and a pencil to mark on
the angled sides and then cut them on the
bandsaw, using the fence to keep a straight line
and had the table at an angle so the cut was
correct. I decided after three cuts that it would look
better if the back was vertical instead of angled, so
I didn't make this last planned cut. The fan is
controlled by a variable resistor which needs
somewhere to hide the large base section of the
component. I chose the location and drilled an
8mm hole all the way through the wood, I then
used this as the centre of a 22mm hole which I
drilled using a forstner bit going only around 8mm
deep. I then carefully used a thin chisel and a
mallet to cut away an area for the wiring and extra
shaped parts to go so the potentiometer fitted
inside the base.

MANUFACTURE DIARY (4)

I used a piece of pine to make the back pillar. I had to use the band saw to cut
the pillar down to the correct dimensions. I then used the veneer curve to
draw the correct shape onto the top of the pillar. Before I cut this shape
out I measured 35mm down from the top on the thinner long side and
marked the centre of this new rectangle this will be the centre for the
axel and bearings holes. I cut the vague shape of the top of the pillar on
the hegner saw and tidied it up down to the line on the disk sander I had
the veneer curve next to me as I wanted to make sure the pillar fitted
really accurately. When I was using the disk sander I wore goggles to
protect my eyes and had a high power extractor vac to remove as much
saw dust as possible from the air. I centre punched the cross I drew
earlier and drilled a small pilot hole all the way through the wood, I then
used this as a centre for the two bearing holes which I drilled using a
28mm forstner bit going 7mm deep in either side. One side wasnt as deep
as I though even though I marked on the drill bit, so I will need to make
sure I make space in the panel that goes on the side this bearing is on.
I needed a block under the pillar to give the veneer curve something to connect
to so I used the bandsaw to cut out the simple rectangular piece of scrap
pine.

MANUFACTURE DIARY (5)

The underside of the base needed space to hide the
wiring out the way so it would sit flat, so we used
the router table to cut a groove from one end all the
way along up to next to the potentiometer hole. I
then carefully used a chisel to join this groove to
the potentiometer hole. The motor was just above
the chiseled cut so I used a thin drill bit to drill
through so the motor wires were tidyly moved out
the way.

The two diagonal holes at the bottom of the middle

picture are ones for the dowel joints I used to
connect the pillar, pillar base and the base
together, this would ensure they stay inline at all
times. I used wood glue and masking tape to hold
all the pieces together as I glued them up.
Once dry I sanded the faces that would be visible up to
240 grit and then coated the oak faces with Danish
Oil to make it shine.

MANUFACTURE DIARY (6)

I sprayed the 3D printed blade holder with a grey priming
paint and left it to dry overnight. I then sanded the
blades so they became smooth and used the same
oil as on the oak for protection. These were glued
together using a 2 part epoxy for strength.

To make the blades turn I used a drive belt from a

disassembled printer. I cut it to length and used a
tube of heat shrink wrapping to seal the connection,
to give a bit of extra grip on the axel I used a file to
rough up the area where it would be touching the
belt directly above the motor gear.

TESTING AND EVALUATION

My product..
Aesthetics

..will fit the retro-futuristic style.

..wont copy an existing product but clearly shows inspiration from other products and ideas of the movement.
..must be attractive and eye catching without detracting from the function. The belt idea is good but sometimes is ineffective

Cost

..will not cost more than my clients budget & I will use school tools and machinery with care so not to break saw blades etc.

Customer / Target Market

..will suit all the needs of my client.

..must make the customer happy so they dont sell it back.
..will be aimed at people with high quality taste who need a fan.

Environment

..must be simple to move small distances and strong enough to not break when knocked or nudged. The axel and blades are a
little fragile so care is required.
..must fit in a relatively small space on a approx. 3m square desk.

Safety

..must not have exposed live wires with no insulation with high current flowing, this should be easy as it will be battery powered.
..will have all joints and fixings tested to ensure they dont come apart or come loose at any point in the foreseeable future.

Size

..must fit on a relatively small desk so should be no larger than 300 x 300 x 200mm. It can be awkward to carry as it isnt a
standard shape.
..must not be overly heavy so it can be moved with relative ease.

Function

..will have spinning blades to create an artificial breeze to gently cool the user.
..must look good even when not in use so it can be left out as an ornament as much as it is a useable appliance.

Materials

..will use shiny hard woods and curved veneers to match the style more.

Testing AND EVALUATION

Client Evaluation
What my client likes?
Starting with aesthetics; my client really likes the look of the blades as they look very steakpunky and make the style very obvious. He also commented on the veneered curve saying it is
very nice and makes the back section look very clean as it looks very specifically made and assembled (implying the curve flows into the base very well). He specifically
mentioned the visible grain of the base as it really adds to the steampunk feeling and looks and feels [to the touch] excellent. The product will be used in an office or home office
environment my client says it will fit into my space very well as it is small enough and compact to fit on his desk as well as looking very distinctive and conspicuous but not so
that it is garish. My client noted the visible motor and wires and said that they are very effectively used to subtly show the style. How could I not mention the belt driven idea, it is
excellent and I am very happy it was used in the final product.
Improvements?
When asked what could be improved my clients immediate response was that the variable resistor is too strong that is to say that it turns almost fully before powering on the motor at all,
but the last section does allow the speed of the motor to be controlled to a certain degree. Continuing this idea is that the motor doesn't turn quite as fast as it probably could, this
could be due to a power supply that isn't suitable (as the printer it was removed from probably fed it 12v instead of the 9v it gets from the battery). He also commented on the small
wobble in the fan blades as it spins this can be fixed by 3D printing a new blade holder or making the blades all one piece of material, he suggested acrylic that was heated and
bent to make a seamless and smoother but maybe less attractive front. The exposed wires could have a piece of metal in front of them to make it look more in the style, they
should still be visible but partially protected.

Functionality?
The fan provides an ample flow of cool air across the user and the variable resistor does control the fans speed to a degree (see improvements). My client said it works like a fan should
and the blades aren't so big that they get in the way of me working which is very good to hear as it was designed to be small and effective. The base is large enough that it wont
fall over but not so large that it is unnecessary and wasteful of wood..
My Evaluation
Changes/Modifications
I think my product came out as a success. It looks excellent and fits the Steampunk style incredibly well as well as functioning as a fan. The floating look add the to effect as well as the
blades which, I agree with my client, really complete the look. The motor isnt as powerful as I would like but it does work and is a useful cooling device. The axel could spin a bit
faster when it isnt on load as this will make it work better and spin more freely.
Mass Production
To make this product able to be mass produced it would have to be partially simplified to reduce the manufacture time. For example, the back pillar (including the veneer and the extra block)
could be all made of one solid injection moulded part for speed and cost efficiency as this part would not be seen. The base and motor stand could be cut using a custom made
machine so they are identical and fast. The base would start as a board or a plank and then sent through a series of custom cutting machines to cut them to size then with the
angled sides. The motor stand would start in square stock form and then cut and drilled. The electronics would probably have to be put in by hand or for the circuit to be rewired so
the wires dont have to be hidden under the base. The axel could be made on the CNC centre lathe and the blades could be cut from thin sheet material with a die cutter to
manufacture many in a short time frame.

TESTING AND EVALUTION

Improvements
My client commented on the exposed wires by the motor and said it could be improved
by having a metal grille around the front to leave them visible but protected as well
as adding a extra material to the design which would hugely improve the look. I
agree that adding this in will add a new look to the product, I think if I were to
remake the product I would certainly add this in. This addition is purely aesthetic
but I think it would make the style of the product very obvious and also make it
look like the motor is warm and is dangerous.

I think my product would benefit from being able to be tilted back and forth to give a more
precise airflow for the user. This would be a simple addition as I can use two
thinner layers of wood on the underside with a hinge at the back and the user
would simply place a small piece of rubber or anything to keep the two separated
to hold it at an angle.

Some more improvements would be to have a more powerful motor to increase the
speed of the blades and therefore the amount of air that is pushed per minute,
which will increase the usefulness of the fan. My client also suggested having the
veneer curve the same colour as the base to make it more subtle and bring out
the contrast with the blades and the centre of the blades.