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At The Blandford School mobile floodlights are required
during any night time events. Whether or not you buy,
own or rent mobile floodlighting (and the fuel thirsty
generators) they’re extremely expensive whichever way
you look at it. Their price is only one downfall, as they
also have a damaging impact on the environment by
burning up fuel. Not only their impact on the
environment can be seen as a downfall as they are
unsightly, costly and the generators are loud and emit
odorous fumes. One place at The Blandford School
where an opportunity for a lighting solution comes to
mind is outside the front entrance. This is the main
reception for events, and therefore requires a mobile
light during such events. Whereas a permanent wind
powered light could be installed. This would not only
look a lot more attractive but would also show the effort
the school goes to, to protect the environment (as well
as the solar panels the other side of the block.)
-I am aiming to design and manufacture a fully
functional prototype wind powered street light. To
be used at The Blandford School to illuminate the
main reception. My design will require a series of
tests and smaller models to ensure the plausibility
and complexity of it is achievable and viable in the
terms of costing.
-The design must appeal to both school children
between the school years of 7 and 13 as well as
teachers, parents and anyone else visiting the
-I shall aim to produce a design that is in keeping
with schools efforts on becoming a more modern
and environmentally friendly place.
-Although my design will be aimed at the school in
general, my specific client shall be the head
teacher Sally Wilson, who has agreed to liaise and
discus ideas with me about the possible future
instillation of the light.
-best fan type?
-full size or scale prototype?
-fit product around clients needs and requirements
The Sun heats our atmosphere unevenly, so some patches become warmer
These warm patches of air rise, other air blows in to replace them - and we
feel this as wind blowing.
We can use the energy in the wind by building a tall tower, with a large
propeller on the top.
The wind blows the propeller round, which turns a generator to produce
electricity via the rotation a magnet through a copper coil.
Initial construction thoughts:
I am aiming to use recycled and recyclable materials when possible as this will cut down on CO2 emissions produced in the creation and shipping of new
products, as well as not adding any strain to resources. To generate the electricity I may use either a second hand bike dynamo or the generator located inside
a wind up torch as they would be perfect to attach to the rotating blades, as their original function was to spin a magnet through a copper coil, inducing
electricity created by the spinning of a cog or wheel. This electricity is then either used directly through a light, or is stored in a battery so that it can be used
The materials I use to make my product must be of good enough quality so that
components will be durable and withstand a long life of working. The moving parts of
my design must be well secured and made of strong materials that will not break over
time. It’s essential that not only my client likes my design but also the school students.
I will aim to design my product in a modern style but keeping the manufacturing as
simple as possible.
15-Jul 29-Jul 12-Aug 26-Aug 09-Sep 23-Sep 07-Oct 21-Oct04-Nov18-Nov 02-Dec 16-Dec 30-Dec 13-Jan 27-Jan 10-Feb 24-Feb
Finalise the client and their needs:
Research into project: holidayholiday
Initial designs and client feedback:
Making and modelling:
Further tests, models and CAD
Present work to client for feedback:
Make any nessisary changes:
Evaluation and conclusion of Project
DESIGN BRIEF ANALYSIS
-Wind powered light.
to modern living in which style
and the environment are both
increasingly popular with
Reception at the Blandford
School. To light up ground for
Will ensure the product is safe
during it’s operational life span.
Schools, specifically The Blandford
School. For a free light source.
The quality of materials,
depending on my price limit ,
recycled where possible to fit with
Physical size, colour and shape.
Should appeal to teenagers to
promote the values of protecting
could be taken further and used
along roads and streets in areas
with a fair amount of wind.
Electrical components will be fully
insulated and rotating blades will
Must be designed to fit with
location of its intended use.
Could be made from aluminium
sheets with polymers used for
electronic component housings.
Type of turbine, vertical axis or
horizontal and fan type.
This page addresses key issues I will have to address throughout the designing and
manufacturing stage of my wind powered light.
TIMESCALE To ensure I finish my product on time, I will am to keep as close to my Gantt Chart as possible, putting in extra hours to deal with any unforeseen errors.
My design will be aimed as a single product at my school, to illuminate the reception area. But if it were to go into mass production I would aim it at county
councils to be installed as street lights.
FUNCTION The function of my design is to convert wind energy into light by turning rotor blades connected to an electric generator which in turn charges a battery.
I will aim to keep the main section of my product (the rotor and light) as small and compact as possible, fitting it around the dimensions of the battery and
electric generator. If my product is successful and weather proof I will then install it in the school grounds, I will then have to attach it to lamp post.
DURABILITY My light must stand up to British weather, therefore being water tight and structurally able to withstand impacts from birds and tree debris.
AESTHETICS I will aim to keep my design as simplistic as possible, with function as the main concern, still holding aesthetics in high regard.
Where possible I shall use reclaimed and recycled materials (as this also fits in with the sustainability aspect. ) Whether or not I manufacture my product from a
combination of polymers or metals will depend on my clients wishes.
SAFETY I will ensure all electronics are enclosed and sealed from water, whilst the rest of the product conforming to the required British standards.
The manufacturing costs would be dramatically reduced if my design was to be mass produced as the production could make use of buying materials in bulk and
would therefore reduce costs. As I am only making a one off product I shall still aim to keep costs low, but not as low as they would be in mass production. I will
aim to spend no more than £50 on my product.
The main aim for this product is to create free clean energy in the form of light. Therefore I shall base my project on sustainability and environmental factors such
as: having 0 air miles in my design with none of the materials I use coming from over sea, using recycled components and using materials which can be recycled.
QUANTITY I shall aim to produce one working prototype product.
TESTING I will make and model multiple designs, finding the most simplistic and efficient design before I begin manufacturing.
ENVIROMENTAL AND FINANCIAL IMPACTS OF STREET LIGHTING
In 2011 the 9 million street lights in the UK cost £110 million on electricity bills to power.
Nottingham county council released this statement: “The electricity bill for street lighting has increased dramatically from £1.05m in 2004/05 to
an estimated £6m in 2015/16 and, over the long term, energy prices are likely to continue to rise. Meanwhile the County Council is predicting
that it will have to take £150m off its current budget over the next three years to deal with the financial pressures it faces.”
Dorset county have recently refitted the old inefficient sulphur street lights with whiter and brighter LED ones. Despite being a lot more energy
efficient they still cost a lot to manufacture as well as the cost fit the new ones and to transport the old ones to be recycled, on top of all this
they still do require the burning of fossil fuels to produce the electricity required to run them
“Every time we switch on a light or turn on the central heating, or even eat a hot meal we use energy. Whatever kind of fuel we use, whether we burn it directly
or indirectly by buying electricity generated from fossil fuels (coal, oil or gas), we are releasing Carbon Dioxide (CO2) into the atmosphere. CO2 is one of the
main gases that contributes to global warming, which is now scientifically recognised as a real threat to today's climate. This doesn't just mean warmer
summers and milder winters, global climate change is responsible for there being more floods, storms and droughts around the world than ever before.
Over the past 20 years, scientists have gathered conclusive evidence temperatures have been rising sharply since the start of the industrial revolution, and that
mankind is the main cause of global climate change.” http://www.nef.org.uk/knowledge-hub/climate-change-energy/climate-change
Advantages of Wind Power:
1. The wind is free and with modern technology it can be captured efficiently.
2. Once the wind turbine is built the energy it produces does not cause green house gases or other pollutants.
3. Although wind turbines can be very tall each takes up only a small plot of land. This means that the land below can still be used.
This is especially the case in agricultural areas as farming can still continue.
4. Many people find wind farms an interesting feature of the landscape.
5. Remote areas that are not connected to the electricity power grid can use wind turbines to produce their own supply.
6. Wind turbines have a role to play in both the developed and third world.
7. Wind turbines are available in a range of sizes which means a vast range of people and businesses can use them. Single
households to small towns and villages can make good use of range of wind turbines available today.
Disadvantages of Wind Power:
1. The strength of the wind is not constant and it varies from zero to storm force. This means that wind turbines do not
produce the same amount of electricity all the time. There will be times when they produce no electricity at all.
2. Many people feel that the countryside should be left untouched, without these large structures being built. The landscape
should left in its natural form for everyone to enjoy.
3. Wind turbines are noisy. Each one can generate the same level of noise as a family car travelling at 70 mph.
4. Many people see large wind turbines as unsightly structures and not pleasant or interesting to look at. They disfigure the
countryside and are generally ugly.
5. When wind turbines are being manufactured some pollution is produced. Therefore wind power does produce some
6. Large wind farms are needed to provide entire communities with enough electricity
PAGE SUMMARY: On this page I have looked into other existing products and designs. The majority of wind powered lights I have found online are all CAD
concepts, very few have actually been made, and of those few the majority are one off products, not batch or mass produced. When looking on Google
for “Wind powered street lights” in the “shopping” section there were none for sale, the closest I could find were small garden ones on Amazon.
This lighting solution, like many of the others is only a computer concept. The design itself can be seen as an art peace as well as a functional
product. It is a very attractive piece of which would be happily welcomed into an urban environment, unlike the generic wind turbine which is
widely regarded as unattractive. This product not only uses wind power it also uses solar energy. Due to this, this product would be better suited
in a sunnier climate than Great Brittan.
Unlike the last design, this one was actually manufactured as a one off product, out of galvanized steel and aluminium sheets. Unlike the last
design this one is focused much more on practicality rather than looks. I believe that a design compromise between the two would be best,
as it would still be aesthetically appealing whilst being fully functional.
Due to its fully metal construction and the fact it is a single sand alone product, it would have cost a lot to produce, as well as not containing
any recycled materials.
This design, like the fist one, is only a CAD animation. Also like the first one it features a solar panel as well as a wind turbine. The key
difference between this design and the other two is the style of turbine blades. This one being a horizontally orientated design, meaning
that it must turn to face the wind, whereas the other two are always facing the wind. The design of this model is very minimalistic with only
one colour ad a lack of elaborate shapes, meaning its contraction would be more difficult than the first one..
CLIENT FEEDBACK TO RESEARCH: Adam has clearly completed a lot of research and has focused on what matters to us as a school. Price is always key but quality and style
should not be compromised. Our new reception area is contemporary and minimalist in style and the light needs to be designed to fit in with this. Lighting across the site is difficult
so as much light as possible needs to be produced by this product.
1) My first design is a basic Google Sketchup
model which features a simple and
understated look. This design features a
vertical rotary system, as do the others on this
page, a drive shaft would come off the
spinning blades indirectly to a generator via a
cog or pulley system. The colours of this design
wouldn't fit completely with the general
mauve/burgundy colours associated with The
Blandford School. Despite this, I believe the
simplicity of both the colours and the design
display a minimalistic feel, although this is an
issue as this product is designed to go at the
front of the school, and should therefore hold
aesthetical value highly.
2) The second designs shares
many features with the first, such
as the arrangement of the rotor
blades driving a generator, in turn
charging a battery and powering a
light, with all the components
stored in the base of the turbine
housing. However, this design
contains a vacuum formed lid,
rather than one assembled out of
layers of polymers. Furthermore,
this design features a different
type of rotor blades, in this case
they are two semicircles which
catch the wind.
3) My third concept has taken
the environmental factor even
further , using a tree to support
the turbine and light, rather than
manufacturing and installing a
post. This design is limited to
locations with an abundance of
trees near to where the light is
required, and would therefore
be unnecessary at the
Blandford school as the area I
have proposed the installation
of the light is free of trees.
4) My fourth idea would be the
simplest and sturdiest idea. The four
supporting beams on each corner
would be stainless steel tubes with
threaded ends screwed to milled
end caps. The main body of this
design would be made from oak
planks, cut to size and coated with a
weathering agent. The turbine
blades will be the same simple
design as the first one, with multiple
lengths of laser cut acrylic fitting via
a mortise and tenon joint to a
circular acrylic disk.
PAGE SUMMARY: Out of my four designs on this page, I prefer the first two due to their simplistic and circular design, both being similar in construction differing with the
types of blades and the amount of them. Although the 3rd one would be the most environmentally conscious eliminating the need for a stand and base due to the straps
temporally fixing it to the tree. However, this concept would be inefficient due to the tree reducing the amount of wind which would be utilised by the blades.
INITIAL DESIGN MODELS
LDR on the top. Light is inactive when sunlight is on the lamp, when it
gets dark the light activates. Turbine housing.
Battery, circuit board and Dynamo housing.
Super bright LED’s in translucent housing.
I began by looking into the turbine housing and blades, making similar versions to the Google
sketch up design below. I created these models above out of MDF and acrylic sheets, using
polypropylene to act as the rotor blades. In doing this I found these designs to be very inefficient
and also very easy to catch the wind in the other direction and therefore stop spinning. I used the
motor and circuit board from a rechargeable torch to attach to the drive shaft and produce light. I
found that a redesign of the rotor blades was essential. One final drawback of the models is the
need for bearings so that they run even smoother.
To the left is where I intend
my final product to go. This
is so that it illuminates the
main reception as well as
being one of the first things
visitors see when entering
the school. Its aim is to
reflect the schools
image to visitors and
Despite being an inefficient
system, I shall attempt to
improve the blades while
keeping the same overall look to
the design, as I believe these
colours and shapes look very
aesthetically pleasing while
connotations and being quite
CLIENT FEEDBACK TO INITIAL DESIGNS: I like the style of
Adam’s product so far, it builds on the contours of the building and
will not be an eyesore, it will more likely be a ‘talking point’ for
visitors. The testing and changing of the rotor blades is good and
helps provide me with confidence that the final design will meet
Vertical-axis wind turbines (VAWTs) are a type of wind turbine where the main rotor shaft is set vertically and the main components are located at the base of
the turbine. Among the advantages of this arrangement are that generators and gearboxes can be placed close to the ground, which makes these
components easier to service and repair, and that VAWTs do not need to be pointed into the wind. The Savonius turbine is one of the simplest turbines.
Aerodynamically, it is a drag-type device, consisting of two or three scoops. Looking down on the rotor from above, a two-scoop machine would look like an
"S" shape in cross section. Because of the curvature, the scoops experience less drag when moving against the wind than when moving with the wind. The
differential drag causes the Savonius turbine to spin.
FURTHER RESEARCH AND MODELLING
After my initial models not being very good, not spinning without the help of a hairdryer, I
decided to look into the Savonius rotor. Using a band saw I cut a section of Pringle tubing in
two and then laser cut the turbine housing from 4mm corrugated card, using a 4mm mild
steel rod I then glued the rod to the blades and cut a plastic tube to act as the stem of the
lamp. Despite not having bearings and the crude construction and imperfections of hot glue
adhesive, this model worked far better than the other two. Not only did it catch the wind a
lot more than the others, it only spins in one direction, meaning unlike the other designs this
one won’t be limited to the wind direction.
-As the blades do not cut across the
airflow, there is less stress on the blades.
-Lower maintenance requirements than
traditional designs as there are no
electronic systems to control blade pitch or
-No gearbox and no brake pads means easy
maintenance and no expensive parts to
-Wildlife friendly compared to traditional
designs as there are no flight windows
between rotations, keeping birds away.
-Can be scaled up and down making it
suitable for industrial or domestic
embedded generation scenarios.
BELOW ARE EXAMPLES OF SAVONIUS SYSTEMS:ADVANTAGES:
Identical top and bottom
laser cut corrugated
cardboard disks with a
4mm whole cut for the
mild steel rod in the
centre and two engraved
semicircles so I knew
where to adhere the
Two laser cut corrugated
sections which hold up
the top section of the
Pringles tube cut down
the centre on the band
saw to act as the blades
for the Savonius rotor.
Further laser cut
sections which act as a
housing for the spinning
blades as well as
supporting the tube.
uPVC tubing acting as a
guard to the steel rod.
Glued to the inside of
sections which hold it in
Mild Steel drive shaft
glued to the spinning
blades with an epoxy
After the success of my cardboard model on the previous page, I decided to make a housing for the generator and the circuit board. Below is the process in which I made it.
Initially I designed the component housing around my previous cardboard model on Corel Draw X6 and then laser cut it out of 4mm acrylic. I also cut out s series of cogs to gear
up the speed of the generator when spun by the drive shaft. I then temporarily glued in place the circuit board and LED’s to the acrylic . Due to the tension caused by the elastic
band on the cogs, it caused the rotor to slow , if I had used a bearing instead of simply allowing the cardboard to rub then I believe it would spin a lot more freely.
I then began to make a stronger model (as the card one rubbed when rotating and felt very flimsy.) I decided to cut an aluminium coke can in two and use these sections for the rotor. The
top right image on this page is a corrugated cardboard test of the MDF housing below (I cut it from card first to ensure that it was drawn to the correct dimensions before cutting into the
more expensive MDF.) Once I ensured my Corel drawing worked, I then cut the same pieces from MDF as to give my model more structural rigidity. I had to cut and thread three lengths
of 4mm mild steel rod, two to support the top of the turbine and one to act as a drive shaft. I then cut a small length of PVC tubing to enclose the driveshaft, adding even more structural
integrity. This model worked far better than the previous one, but due to the friction caused by the rubbing of MDF to MDF and steel to MDF, slowing down the spinning, bearings will
definitely be needed in the next model. The image in the bottom right hand corner of this page is a successful test of what the final circuit board will need to be like.
GOOGLE SKETCHUP MODELLING
After the success of my past two Savonius models, I began redesigning my
Google Sketch Up model. With my new design I put in a lot more attention to
detail when creating it, creating a proper turbine housing (unlike with the
initial SketchUp design.) I will aim to use recycled and recyclable materials
when possible, to in keep with the eco friendly theme. When possible I shall
try to reuse items such as bearings, battery and the dynamo. This design
would be manufactured using layers of laser cut 9mm acrylic sheets, with two
Polypropylene blades created by cutting a sheet to size and securing it in two
semicircle holes, one at the top and one at the bottom of the blades. The
cover on the top would be created by vacuum forming an acrylic sheet over a
curved mould. The battery would be stored in a specialist jig cased inside the
bottom part of the housing, with the generator connected directly by cogs or
a chain to the driveshaft.
With this design I have
included two supporting
beams acting as the turbine
housing to hold the
protective roof section in
place over the blades.
Furthermore, the Savonius
blades have been included
for maximum efficiency. I
have also focused more on
the colour scheme in this
design, aiming to replicate
the colours of the sky so
that it blends in better with
its environment and isn't an
With the initial design
I forgot to incorporate
the housing for the
blades on the initial
inefficient, being slow
and libel to rotate
either direction. In
addition, the design
was too simplistic and
the colours were too
basic and would have
looked out of place on
the school grounds.
Light dependant resistor
on the top of the turbine
housing which will
activate the lights when
the ambient light falls
below a set luminosity.
Supporting beams made
from either Mild Steel or
Acrylic rods which will
hold up the top section
of the turbine housing.
New blade design-
Savonius blades. Made
Polypropylene or a piece
of Acrylic tubing cut in
Improved design for the
lamp post, applying a
metallic texture onto the
CAD design, with the
final post most likely
being Galvanised Steel.
FURTHER MODELLING DEVELOPMENT
I decided to create a more refined and functional Savonius model so that
I understood the procedures required to make the blades myself, rather
than cutting a tube in two. I initially cut two identical sheets of
aluminium and then measured the length and thereby worked out half of
the circumference of a whole circle. I then laser cut a the correct sized
semicircle out of 6mm MDF and used it as a guide to bend the
aluminium sheets to. Using the sheet rollers I bent the two sheets into
perfect semicircles. I then drew a circle on Corel Draw X6 with the two
cut outs for the blades and cut it out of 4mm corrugated cardboard.
After gluing the two blades in place I found this to be an extremely
effective and efficient rotor system.
One thing I did find with the Savonius rotor is that when it stops
rotating it can end up facing side on to the next oncoming wind,
and It therefore struggles to spin again, unless there is a new
direction of wind. Below I have drawn a small diagram of this
problem. To solve this I may have to design a third rotor blade so
that it will not only function in any wind direction, but the third
blade would increase the surface area in contact with the air,
thus increasing the speed of rotation.
PROBLEM AND SOLUTION:
CLIENT FEEDBACK TO
MODELLING: As a client
I am impressed by the
detailed work going into
the design of this
product and am pleased
Adam is concentrating
on efficiency and
aesthetics. The contours
continue to match those
of the building and I like
the ease of attachment
to a structure (eg the
basketball post). The
eco friendly theme will
appeal to students, staff
Once I decided I needed a third rotor blade for increased efficiency, I began designing a new system. This time, instead of
cutting the spaces for the blades into a large circle, I designed the housing of the blades to be as small and light as possible,
decreasing weight and therefore requiring less wind to move it. This new design also allowed me interlock the two sections
together on the laser bed, thus reducing waste materials. I included strengthening beams to ensure the flexing polypropylene
blades don’t break the MDF whilst trying to return to their original shape. I laser cut a 4mm hole in the centre of the housing
for a mild steel rod to be glued in place. As this was only a model, I only cut out very small sections to act as the blades, the
final design will be a lot taller to catch more wind. I then moved on to design the housing for the turbine. I did this by laser
cutting 3mm MDF for the main section and 6mm for the three support beams. With this design I included small bearings to
which I accounted for and cut out two tight fitting holes in top and bottom section, allowing a tight friction fit. I am extremely
pleased with the outcome of this design, as it is both the most efficient and aesthetically pleasing design. Even with this model
being very shallow, it still caught a lot of wind, especially when I attached it to a basketball post.
I looked into the sort of LED
lighting cyclists would use
on their bikes. I discovered
that a brand new one
(considering I would be
looking to buy one second
hand) costs around £20. I
then looked into alternative
lighting and found that
powerful surface mounted
LED’s are not only brighter
but significantly cheaper. I
also found a 12V 7AH
rechargeable battery which
when fully charged can run
the 600MA light for 11.6
hours, which is more than
enough for what I require.
For the section under the
rotor blades I designed it
to be a cylindrical tube,
after looking at the prices
for acrylic tubing of the
same diameter I would
need to house the battery
I found them to be far too
expensive. Therefore I
could try to create a tube
by rolling a single sheet of
aluminium and spot
welding it to itself.
As the majority of my design will involve laser cut acrylic sheets I needed to ensure that the
bonding agent used to join two sections of acrylic would be %100 watertight. I tested this by
cutting an acrylic disk to loosely fit an acrylic tube and then sealed the gap using plastic
weld. Although being messy this method worked to ensure the join was watertight. To
reduce the amount of plastic weld required I cut another acrylic disk, this time I measured it
to the exact dimension of the tube (unlike before when I made it intentionally too small )
and the friction fit was enough to hold water at bay. This has shown me I need to be extra
careful when cutting and measuring with my final product as I would like to use as little of
the environmentally harmful plastic weld as possible.
Above is an example of the acrylic
sheet I would need for the two
sandwiching sections of the
turbine, with a thicker 10mm
sheet for the two sandwiching
sections of the turbine housing.
To the right is an example of the
acrylic rods I could use to support
the top section of the turbine
(mild steel rods were used in my
coke can model).
I have decided to look into alternative methods to achieve the tube section needed for my product.
As this is a one off prototype, it would be very cost and time ineffective to create this section from the
two previous methods I had considered (buying a large acrylic tube and cutting it to size, or rolling a
sheet of aluminium into a tube and welding it.) I have also looked into products which could serve as
an alternative, leading me to find this small bin, as it not only fits the size criteria correctly, but it is
also relatively cheap. However, I will probably have to apply a different finish to it, depending on the
clients wishes for colours. Furthermore, I will have to measure and cut a jig to go on the inside to hold
the battery, circuit board and LED.
To the right is the battery I have purchased to power my light. I made sure that I bought not only a
powerful battery, but a relatively small one, as others I have looked at were around four times the
size. It is also perfect as it fits into the housing I have looked into, which is 180mm wide, whereas the
battery is only 150mm in length, and 163mm from corner to corner.
To the left is a bearing which matches the exact dimensions I require, with an internal diameter of
4mm, the same as the mild steel rod I plan on using, and with an external diameter of 16mm. One of
the most commonly used bearings, these types are manufactured with metal shields inserted into the
outer raceway, fitting in closely to the inner race providing protection against light mechanical damage,
some protection against the entrance of moisture, dust and other foreign matter and serving to retain
the pre-filled grease in the bearing. Benefits: Provides light mechanical protection, limits moisture and
dirt ingress, lubricated for life, cost effective solution
PAGE SUMMARY: On this page I have looked into various readymade components which I may use in my final product, in the case of the 4mm bearings I am certain I shall
purchase a similar item, however, in the case of the tube section I am still unsure as to whether I will use this bin (or one like it) or if I'll attempt to make a tube from
bending Aluminium or if I will come across a piece of tubing which will fit my criteria. Similarly with the battery, although purchasing one, I am still unsure of its suitability
for the wind powered light.
Taking both function and aesthetics into account, I have re-
designed the turbine blades. With this updated design I
have focused more on smoothing out the areas with sharp
angles, as this will reflect the look of nature, with smooth
flowing curves. Furthermore, I have added an extra
strengthening beam behind each rotor to ensure a higher
structural integrity. in addition I have added spacers in the
slots for the blades, as the flexing of the polypropylene was
causing structural weaknesses along the blade, whereas
with these extra sections of material, the polypropylene
won’t be able to flex open the gap, meaning gluing will be
Taking both function and
aesthetics into account again, I
have re-designed the turbine
housings, as before I have
focused on curves and more
natural shapes, eliminating the
harsh right angles. Furthermore
I have decided to use acrylic
rods rather than a laser cut
rectangular section to support
the top of the turbine, as either
rods or possibly sanded down
rounded rectangular sections
will consist of curves and
therefore look more attractive.
Unlike my initial plans to laser
cut these sections out of acrylic,
I may try to mill them out on
the three axis milling machine,
using a Pro Desktop file to
create a 3D CAD design,
allowing me to add bevels to
the edges, rather than the 90⁰
wedge created by laser cutting.
Above is a scanned in image of a sketch for my
final idea. This idea incorporates the changes I
have made on this page, with the curves and
additional structural beams. I have also coloured it
in with the colours my clients agreed to, matching
and blending in with the sky as much as possible.
On this page I have taken the sketch from my previous page and created a Google SketchUp model, focusing
on what my final design will look like, drawn to scale with the colours agreed to with my client. I have also
displayed my design in various ways, including X-ray and wire frame to show the interior of the housing unit
at the base.
CLIENT FEEDBACK TO DESIGN CHANGES: Adam is clearly focusing on how sturdy the product is, and he needs to as this will
be very important – the area outside Reception is not covered so it will be exposed to all weathers.
CAD DESIGN ANALYSIS
Laser cut 5mm translucent blue Acrylic
will act as the top and bottom sections
for the turbine housing. This is due to
the aesthetical value of laser cut
translucent Acrylic on top of the fact that
it is a thermo plastic and therefore
recyclable, meaning any off cuts which
can’t be used can still be recycled.
Laser cut 1.5mm Stainless Steel pieces
which will hold the Polypropylene blades
in place. Brushed with fine wire wool for
10mm x 10mm x 500mm Acrylic rod cut
to size and glued using an Acrylic weld
to the 5mm translucent blue Acrylic.
These rods act as the supporting beams
which hold up the top section of the
turbine housing as well as being visually
appealing with the transparent Acrylic
reflecting and refracting light which falls
210mm x 240mm x 0.8mm blue
Polypropylene blades with specially
designed locking tabs to ensure that they
are securely fitted to the Stainless Steel
without the requirement of an adhesive.
As with the Acrylic sheet , I have chosen
to use Polypropylene as any off cuts too
small for somebody else to use can be
uPVC tubing cut to size on the band saw
and then sprayed with a white primer
base coat, followed by several layers of
Milled Aluminium ‘T’ shape sections
which will slot into the top and bottom
of the uPVC tube. The top one will have
three holes cut into it so that it can be
attached to the 5mm Acrylic via three
identically cut holes. The bottom piece
will have a hole cut into it for the lens of
the LED as well as for the pole which will
hold the entire object.
Supporting post possibly made from
galvanised steel. However this will not
be important in my design process as I
am focusing on the aesthetical aspects
of the main sections of the turbine and
Due to a range of testing and experiments with trying to run a wind up camping light directly off a drive shaft from a spinning rotor, and coming across
complications with the electrical components, I have decided to take my design in a slightly different direction. I now aim to make a .75 scale spinning
prototype as before, only now I do not intend for it to charge a battery and power a light, it will now be a purely non functioning model with a separate bread
boarded circuit board to show how the light dependant resistor will function as a switch.
To the left is a screen shot of the
initial correspondence between
myself and external contact who
works at a local metal working
company. I have sent a file of an
attachment of the top and bottom
sections of the rotor, as I had
indented for these two sections to
be laser cut out of stainless steel
rather than acrylic as this would
add a more premium look to my
product. Furthermore, the
stainless steel would be better
suited for the function than acrylic
would, being able to withstand
impacts without shattering . Mr
Open has stated that he his unsure
which thickness would be ideal to
cleanly cut the pieces whilst still
retaining structural integrity,
however he will test out a 2mm
thickness first, as we both believe
this will most likely work best.
CLIENT FEEDBACK TO PLAN CHANGE: I am pleased Adam has taken the advice of an industry specialist and is keen to try different approaches based on the
STAINLESS STEEL SECTIONS
On this page is the continuous communication between myself and an
external metal working contact . After clarifying a few issues, such as the
thickness of material and the scale of the drawing to be cut I then
received an email stating that they had been cut.
I am extremely pleased with the outcome of the laser cut sections of
stainless steel , as they are far better than I had imagined, being thinner
yet stronger than I had thought, whilst being identical to the CAD file,
despite my expectations that cutting such thin lines into such thin
material might lead to it welding itself back together. Admittedly there
were a few inconsistencies and imperfections , however these are
extremely fine details that can only be observed from close inspection.
Firstly, I did laser cutting tests on a sheet of 0.8mm
thick polypropylene, changing the power level of
the laser to reduce the melted burrs which build up
along the path of the laser, making it harder to slot
into the sections of stainless steel. Once satisfied
with the power of the laser I then cut out a 300mm
piece with the specific grooves to fit into the steel.
Although fitting reasonably well I found that due to
its length it began to bow in the centre, which then
led me to re-design a smaller blade.
I then decided to re-design the length of the blades to 200mm in
an attempt to reduce the bowing effect created by the previous
blade . I found that reducing the length of the blades worked
well, as now there was no bowing. However, I found it extremely
difficult to slot the blades into both sections of stainless steel, as
when one went in the other popped out. Furthermore difficulties
I have encountered include attaching the blades once in position,
as using an epoxy resign which would be the strongest way of
attaching the components together would also be messy and
leave unsightly blobs of glue.
Re-designing the top and bottom sections of
the blades so that they not only slotted into
the steel groves without easily coming out but
fit so well that they required no external
adhesive at all proved to be quite challenging.
Requiring three attempts to create sufficient
locking tabs I was eventually pleased with my
design which allowed the blades to be slotted
in place with the additions of the locking tabs
making it almost impossible to simply pull the
blade out (without breaking it)
9457PAGE TWENTY ONE
For the static top and bottom sections of the
housing for the rotor I have decided to use a
sheet of 5mm Acrylic , which I will then laser cut
the CAD design from. To the far left is a test
piece I cut from a piece of clear 5mm acrylic to
ensure the correct measurements. Despite
being far larger than I need, the 1000x600
sheet is the smallest sized sheet which would fit
the pieces I need cutting on it. Due to this I have
ensured the excess Acrylic does not go to waist,
as a classmate of mine is splitting the piece with
me. I have decided to go with a translucent blue
sheet as this is in keeping with the idea of it
blending into the environment, using colours
associated with the sky .
Light Blue Tint
1000mm x 500mm
SHEET OPAQUE ICE
Sheet Size: 650mm x
1100mm x 0.8mm
Based purely on aesthetics I
have decided to use 10x10mm
clear acrylic rod to act as the
supporting beams to hold up the
top section rather than using
the same blue acrylic.
For the three blades I have decided to
use a sheet of 650 x 1100 x 0.8mm
Polypropylene which I will then laser
cut the CAD file from. As with the
Acrylic sheet , this sheet far exceeds
my requirements . I shall use the
smallest amount of material I can,
reducing the waste off cuts between
each piece meaning that there will be
more spare material for other people
to use in the future. Again, as with the
Acrylic, I have ordered blue material so
that it merges with the sky and won’t
stand out too much.
For the base section
which will hold the
lights and battery (and
dynamo in the real
thing) I have decided
to use a piece of u-PVC
tubing cut to size and
sprayed to match the
colours of the rest of
the turbine. I shall
initially spray a white
primer coat and then
several layers of light
blue in order to match
the colours of the rest
of the product..
PAGE TWENTY TWO
STEP ONE: Ensure Stainless Steel sections are laser cut before I begin to manufacture other sections as these are
the main pieces and due to the complexity of the design and my lack of experience with the external metal
working company meaning I don’t know how long it will take them to process the file and cut the sections.
STEP TWO: Apply an even matt finish to the Stainless Steel pieces with wire wool to increase aesthetical value.
STEP THREE: Once materials have arrived, cut 5mm Acrylic sheet to minimum size needed so that it not only fits
on the laser bed but this also means there will be more material for my classmate to use who is sharing the sheet
STEP FOUR: Laser cut out the pieces of 5mm Acrylic and 0.8mm Polypropylene, firstly cutting the files out on
paper to certify the correct sizes.
STEP FIVE: Cut 10mm X 10mm clear Acrylic rod to desired size, guaranteeing that they fit into the laser cut slots in
the 5mm Acrylic.
STEP SIX: Slot the three Polypropylene blades into the Stainless Steel pieces.
STEP SEVEN: Apply an Epoxy Resign to adhere the 4mm Mild Steel rod to the Stainless Steel pieces through the
holes cut in the centre.
STEP EIGHT: Use an Epoxy Resign to glue the bearings in place in the 5mm Acrylic.
STEP NINE: Using a Plastic Cement, adhere the three 10mm X 10mm clear Acrylic rods to the 5mm Acrylic pieces,
around the blades, ensuring that the Mild Steel rod is fed through the top and bottom bearing.
STEP TEN: Once in place, add an external bonding agent to adhere the Mild Steel to the bearings (on top of the
strength of the friction fit.)
STEP ELEVEN: Cut uPVC tube to desired length.
STEP TWELVE: Apply a white base coat of paint to the tube, once dried, spray multiple layers of blue onto the
STEP THIRTEEN: Solder required resistors onto a circuit board with Star LED and Battery pack.
STEP FOURTEEN: Mill out top and bottom Aluminium ‘T’ sections for the uPVC tube to fit into, as well as to
connect the tube to the base of the 5mm Acrylic.
STEP FIFTEEN: Mill out holes for the light in the bottom Aluminium section.
STEP SIXTEEN: Attach the bottom and Aluminium ‘T’ sections to the tube using an Epoxy Resign and secure the
top section to the 5mm Acrylic using three nuts and bolts.
POINT UPDATED SPECIFICATION
To ensure I finish my product on time, I will am to keep as
close to my Gantt Chart as possible, putting in extra hours
to deal with any unforeseen errors.
My design will be aimed as a single product at my school, to
illuminate the reception area. But if it were to go into mass
production I would aim it at county councils to be installed
as street lights.
The function of my design is to act as a scale prototype for
a wind powered light.
I will aim to keep the main section of my product (the rotor
and light) as small and compact as possible.
My light must be tough, however not as durable as if it
were to be an actual working product
The aesthetical value of my design is of paramount
importance and surpasses the functionalities importance as
I am only making a prototype. .
Where possible I shall use reclaimed and recycled materials
(as this also fits in with the sustainability aspect. ) Whether
or not I manufacture my product from a combination of
polymers or metals will depend on my clients wishes.
I will ensure all electronics are enclosed and sealed with no
chance of shocks.
The manufacturing costs would be dramatically reduced if
my design was to be mass produced as the production
could make use of buying materials in bulk and would
therefore reduce costs. As I am only making a one off
product I shall still aim to keep costs low, but not as low as
they would be in mass production. I will aim to spend no
more than £50 on my product.
I shall base my project on sustainability and environmental
factors such as: having 0 air miles in my design and using
recyclable materials when possible.
QUANTITY I shall aim to produce one scale prototype product.
I will make and model multiple designs, finding the most
simplistic and efficient design before I begin
PAGE TWENTY THREE
To the left I have laser cut
the 5mm translucent light
blue Acrylic for the top and
bottom sections of the
turbine housing. These
pieces will hold the bearings
in the centre which will hold
the 4mm Mild Steel rod, they
also contain squares for the
10mm x 10mm transparent
Acrylic rod to be glued in
After I cut the 5mm Acrylic I knew
that it would be an insufficient
thickness to fully support the
10x10mm Acrylic rod, so I
decided to cut further Acrylic
circles with a 10x10mm square
for the rod to go through. This
means that when I go to glue the
Acrylic sections together there
will be more support for the rods,
thus ensuring that they are
Before I cut the Polypropylene blades I
altered the power setting on the laser to
reduce the burr and burning along the path
of the laser. Once I reduced the power
sufficiently I then cut out the three blades.
I cut the section of
1000mm x 500mm
down to 600mm x
400mm so that it fit
into the laser bed,
utilising all the
space when cutting
by rearranging the
two sections in a
way which required
the least space.
To the right is my product after
the first week of beginning
manufacturing. I have
successfully cut all the Acrylic
and Polypropylene that I need.
Furthermore I have also cut and
sprayed the uPVC tube. The
Polypropylene fit well into the
Stainless Steel as did the
bearings into the Acrylic.
- Wire up a battery with the star
- Cast Aluminium
- Mill Aluminium
- Glue all components together
I initially cut the uPVC tube
to 155mm using a band
saw. I desired the length of
150mm but knew that the
blade of the band saw
would not only take off a
few more millimetres but
it would also cut slightly
unevenly and not
Because of this I then put
the tube onto the lathe
and faced the two edges
until they were square. I
then coated the tube with
multiple layers of a white
aerosol primer, allowing
each coat time to dry
before applying the next.
Once fully dried I followed
the same process but this
time with a light blue
In the image to the right I have glued
the bearings in place in the 5mm
Acrylic. Before mixing the two part
Epoxy resign, I masked off the area
around where I would be gluing to
eliminate the possibility of any excess
glue adhering to the surface of the
Acrylic which would have looked
unsightly. After this, I coated the edge
of the bearings with an Epoxy resign
and glued them in place.
To the right I have cut the two 500mm
Acrylic rods into four 240mm rods
using a band saw. I initially measured
the 250mm half way mark on each rod
and then measured back a few
millimetres on each side and applied
masking tape to the areas I didn’t wish
to cut, and then cut on the centre line.
Following this I then used a belt sander
to face off the uneven faces and bring
each rod down to 240mm.
PAGE TWENTY FOUR
Laser cutting the two MDF disks from 12mm MDF
with a following 3mm smaller disk being cut after
Coating the three MDF
disks with polyvinyl
Leaving the three disks to
dry and the glue to set in a
Drilling and threading a
hole for extraction of the
mould from the sand.
Coating MDF mould in
powder so that extraction
Packing sand around the
MDF mould in the Drag
Smoothening the sand of
the bottom layer of the
With the help of a class mate I then packed the
sand around the wooden sprue pins in the Cope
Smoothening the sand on the top of the Cope
moulding frame around the sprues.
Pulling out the wooden
sprues leaving the riser
and runner hole.
Taking the Cope moulding frame off the Drag and
then screwing a screw into the threaded hole so
that I can remove the MDF mould.
Removing the MDF mould and removing excess
sand which crumbled inwards.
Creating a path for the molten Aluminium to
get into the mould and one for the air to escape.
Fastening the Cope onto
the Drag and preparing to
pour the Aluminium
Ensuring all safety
measures are in place and
igniting the flame.
Leaving for a while to
set and then begin to
After an hour or so,
separating the Cope and
Removing the piece
carefully using long tongs
and gloves, then quenching.
Once the Aluminium is molten at
700°C pouring until it fills up
both the riser and runner.
PAGE TWENTY FIVE
Above is my initial
dimensional sketch for the
Aluminium T-section, along
with a Google SketchUp 3D
CAD design. I produced the
CAD design so that I knew
what the final piece would
look like before actually
manufacturing it , using it as
a guide to work to.
After the casting process I had to cut off the two pieces of Aluminium which
were formed in the runner and the riser. After which I filed off any burs and
extruding imperfections and began to turn the piece on the metalworking
lathe. Firstly I reduced the material down to size (since I intentionally made
the Mould oversized so that I could carefully remove the rough outer layer
of Aluminium.) once almost down to the right sizes in each dimension, I
slowed the tool paths so that the finish would be finer than the rough one
achieved my the initial turning. I then applied a shallow bevel to the edges
to eliminate the risk of cuts caused by sharp edges.
Once the T section was to the desired dimensions, I laser cut an MDF jig with
three 4mm holes cut into it to represent where I would need to drill into the
Aluminium. I then used these holes to centre punch an indentation into the
Aluminium before drilling a 3.5mm hole. Once drilled, I threaded the inside
of them with a 4mm tap, meaning that a 4mm bolt would fit securely into
the Aluminium. Lastly, I drilled a 16mm centre hole for another bearing to fit
PAGE TWENTY SIX
I then repeated the casting process a second time to produce a second Aluminium T section. Once I reduced the excess Aluminium and brought the piece down to size, I then created a 38mm hole trough the
centre on the lathe for a steel tube to fit into. I then used the vertical axis milling to bore out a second hole for the lens of the super bright LED, I used the milling machine rather than a pillar drill as there was
no drill bit of the exact size, however there was a bit of the correct size for the milling machine. I then cut two Acrylic sections; one a frosted ring and the other a clear disk. I glued these together and inserted
them into the Aluminium with the lens placed behind, as the minimalistic styling of the Acrylic section surpassed the aesthetical value of the lens.
Next, I began work on the internal and external electronics. I wired a battery pack to a switch and then to the LED with a resistor in
series to limit the current flow. I also applied heat shrink over the soldered wires to ensure there were no exposed areas and that
everything was fully insulated. I also made a small acrylic disk with a section cut out for the two wires which I used to secure the LED
onto the lens inside the Aluminium.
To counter the bowing of the blades (which was so severe that the rotor couldn't turn without
catching on the Acrylic supports) I created a device (below) to ensure the blades remained
straighter. This in turn allowed the rotor to freely spin.
PAGE TWENTY SEVEN
To conclude my manufacturing process I drilled a hole
in the side of the uPVC tube and screwed the switch in
place. Before gluing the Acrylic sections together I
drilled three holes into the bottom piece
corresponding with the holes drilled into the
Aluminium which I then screwed three 4m bolts
through, thus attaching the Acrylic to the Aluminium. I
then proceeded to use plastic cement to adhere the
Acrylic sections together and a two part Epoxy Resign
to attach the Mild Steel rod to the bearings.
PAGE TWENTY EIGHT
PAGE TWENTY NINE
of a single
the cavity of
Explosions- Water, on or in the
mould material , can boil
explosively when heated by hot
Burns- Contact with hot
crucible or molten metal
splashed onto skin can cause
Chemical reaction- Molten
aluminium can react violently
with metal oxides such as rust.
Explosions- The risk of
explosions is high in the
following cases: When
green sand moulds are
used straight from a cold
store or are cooled in
water before being re-
used. Also when plaster
moulds are not
thoroughly dried before
metal can be
ladles or as a
result of an
iron oxide is vey
it is very rare in
Casting should only be
carried out in a dry area,
with equipment designed
for that purpose and
under the supervision of
Observers must also
wear personal protective
equipment and should
be at least two meters
back from the operation.
by turning, facing,
boring , screw cutting,
centre drilling, tapping
and knurling of
primarily cylindrical or
spherical forms from
both ferrous and non-
ferrous raw material ,
possibly using oil based
Trapping- Closing movements between parts
under power feed can present a trapping hazard.
Flying workpiece- Workpieces, chuck keys or
tools can be ejected violently if not held
correctly or if the machine starts unexpectedly.
User injury- Human contact with swarf can
cause cuts or abrasions .
Entanglement- Long hair, dangling jewellery or
loose clothing can become entangled with
rotating parts, dragging the operator into the
power feed are
usually slow, thus
minimising the risk
of trapping which
would most likely
occur when the
machine is being
There is a high
There is a high
risk of putting
fingers in fast
There should be sufficient
space around the lathe to
ensure that the user is not
pushed into the machine by a
passer by. The floor surface
should not be slippery to avoid
accidental slips while using the
machine. Guards over the
moving areas should prevent
anything from flying towards
Process-Use of a
laser to cut
wood, card and
control as an
example of CAM.
Burns- High power lasers can cause severe
burns to skin.
Blinding- Reflective beams can cause
blinding if entering the eye with powerful
Toxic flumes- The use of the laser to cut
PVC generates toxic vinyl chloride.
Polyurethane foams may give hydrogen
cyanide and nitrogen oxides when heated.
Fire- The material being cut may be ignited
by the cutting process.
Burns- The risk
of burning is
the laser beams
risk of blinding
the laser beams
Interlock to prevent the use of
the laser unless the system is
enclosed and the lid is shut.
Servicing should be carried out
regularly by professionals. PVC
and polyurethane should not
ever be cut. The power and
speed settings must be set
correctly. An extractor fan
must be on to reduce fumes
and the chance of fire.
LASER CUTTING: RISK
Fire- If the
provided by the
then the risk of
ignition of the
should be low.
a serious risk.
POINT / UPDATED SPECIFICATION COMMENT
To ensure I finish my product on time, I will am to keep as close to my Gantt
chart as possible, putting in extra hours to deal with any unforeseen errors.
I was able to keep closely to my Gantt chart, finishing slightly ahead f schedule due to the removal
of the electronic components.
My design will be aimed as a single product at my school, to illuminate the
reception area. But if it were to go into mass production I would aim it at
county councils to be installed as street lights.
As my product was initially aimed at one specific client, it has remained the same throughout .
The function of my design is to act as a scale prototype for a wind powered
My final product succeeded at being a scale prototype as I had intended.
I will aim to keep the main section of my product (the rotor and light) as small
and compact as possible.
I was successful in keeping the main components as small as possible, with the obvious exception
of the blades needing to be relatively large, however, my new design for the tree bladed Savonius
rotor was able to minimise the size.
My light must be tough, however not as durable as if it were to be an actual
Because of the materials I was limited to due to limitations of the cost my final prototype it
succeeded in being a scale model, however it was not structurally the same as it would have to be
for the full sized working product.
The aesthetical value of my design is of paramount importance and surpasses
the functionalities importance as I am only making a prototype.
My final product ended up looking almost identical to my final Google SketchUp CAD model and
initial sketches and was extremely aesthetically pleasing.
Where possible I shall use reclaimed and recycled materials (as this also fits in
with the sustainability aspect. ) Whether or not I manufacture my product from
a combination of polymers or metals will depend on my clients wishes.
Although I was able to use primarily recyclable materials, such as the Acrylic and Polypropylene as
well as some reused elements (the uPVC tube) the majority of materials used were brand new
and not recycled as I had hoped for.
I will ensure all electronics are enclosed and sealed with no chance of shocks. All electrical components inside the uPVC tube were correctly soldered and subsequently
wrapped in heat shrink to eliminate any chances of shows or shorting.
The manufacturing costs would be dramatically reduced if my design was to be
mass produced as the production could make use of buying materials in bulk
and would therefore reduce costs. As I am only making a one off product I shall
still aim to keep costs low, but not as low as they would be in mass production.
I will aim to spend no more than £50 on my product.
As my product was a one off and benefitted from the charity of Bristolmaid who supplied me with
the laser cut stainless steel free of charge, I was able to keep the overall cost of my product well
below my initial maximum price limit.
I shall base my project on sustainability and environmental factors such as:
having 0 air miles in my design and using recyclable materials when possible.
I was able to attain all materials and components from mainly local sources with the exception of
Trent Plastics and Hindleys, however even these two locations remained in England, meaning
there are no air miles associated with my product. Furthermore the majority of the materials used
in the prototype are recyclable.
I shall aim to produce one scale prototype product. I succeeded in producing one scale prototype.
I will make and model multiple designs, finding the most simplistic and efficient
design before I begin manufacturing.
I produced a number of different models and tested their efficiency before settling on my final
9457PAGE THIRTY ONE
10mm x 10mm x 500mm square Acrylic rod cut to size and
glued using an Acrylic weld to the 5mm translucent blue
Acrylic. These rods act as the supporting beams which hold
up the top section of the turbine housing as well as being
visually appealing with the transparent Acrylic reflecting and
refracting light which falls upon it.
210mm x 240mm x 0.8mm blue Polypropylene blades with
specially designed locking tabs to ensure that they are
securely fitted to the Stainless Steel without the
requirement of an adhesive.
Laser cut 1.5mm Stainless Steel pieces which will hold the
Polypropylene blades in place. Brushed with fine wire wool
for aesthetical value. With a 5mm Mild Steel rod running
through the centre attached to bearings in the Acrylic.
Laser cut 5mm translucent blue Acrylic housing the Steel
and Polypropylene rotor, with three holes drilled into the
bottom piece for screws to fasten to the Aluminium.
Costing: £20.63 sheet split with classmate, equalling
Laser cut 5mm translucent blue Acrylic sections to keep the
blades from warping, cut from the offcuts of the main
uPVC tubing cut to size on the band saw and then sprayed
with a white primer base coat, followed by several layers
of light blue with a hole drilled near the base for the
Costing: £5 for the spray paint, the tube was free
Cast and milled Aluminium ‘T’ shape sections which slot
into the top and bottom of the uPVC tube. With the top
piece having three holes cut into it so that it can be
attached to the 5mm Acrylic via three identically cut holes,
and the bottom piece having a hole cut into it for the lens
of the LED as well as for the Steel pole.
Costing: £1 for the LED, however the Aluminium was free
due to using reclaimed pieces of aluminium and then
melting them together.
Stainless Steel tube which fits through the central hole cut
into the bottom piece of Aluminium, elevating the rotor off
Costing: Free, due to it being a reclaimed pole from a past
Overall, this project cost me roughly £26, however
this is not an accurate representation of how much it
would cost to produce a full sized working product.
This is down to the fact that I was able to receive
multiple items free of charge, whereas that wouldn’t
be possible if I were to mass produce my product.
Furthermore, my prototype is only a .75% scale of the
intended size of the real product, meaning there
would be greater material costs.
QUALITY CONTROL:1- When cutting the rods I had to ensure
the were all cut and sanded to the exact same length,
otherwise the housing would have been lopsided.
2-5- Designing these sections on a CAD file and laser
cutting them reduced and QC issues as they were cut so
6- When cutting and spraying, accuracy was very
important to ensure a precise finish.
7- With both the casting and the turning process I imposed
QC checks regularly to guarantee the Aluminium fit
perfectly into the uPVC.
8- initially ensured the strength of the tube to certify it
could hold the weight of my product.
9457PAGE THIRTY TWO
9457PAGE THIRTY THREE
CLIENT FEEDBACK TO FINAL PRODUCT
I really am very impressed with the final product. Adam listened to what was required and has focused on what matters in terms of the school. He has taken
our school population into consideration and designed a product which is durable enough to survive in a school with a population of 1000 adolescents. The
quality of diagrams and level of detail should be credited as he has been able to show how the design process has unfolded to a client who does not have a
background in this area. He has thought carefully about audience, the clarity of his work is exceptional. I would have confidence in the product and Adam as
Question One: Based on your initial comments on the design of this
product and its aesthetical appeal, are you pleased with the final visual
Question Two: The rotor section on this prototype is ¾ sized of the
planned real product, with the pole being ½ size, do you feel that a ¼
sized larger rotor section would appear too large (irregardless of possible
Question Three: Do you believe that the addition of wind powered lights
to the grounds of The Blandford School will be welcomed by staff and
Question Four: Would you prefer a compromise of lower quality
materials for a cheaper overall price?
Question Five: Despite the overall colour scheme of the school being
predominantly burgundy in the past, are you happy with the overall blue
theme of my design?
Answer One: Yes, I am extremely pleased with the final product which is extremely
appealing and would suit this environment well.
Answer Two: I do believe larger rotor blades would be useful if the product was larger.
Answer Three: Absolutely, staff and students are always keen to look at ways of using
the natural environment . As Headteacher I am always concerned man-made
products enhance the landscape and the buildings.
Answer Four: Value for money is extremely important. I would compromise on quality if
necessary, we often have to. However, I would need a product which lasts and so would be
keen to discuss longevity with Adam. I would pay more if he could prove this would be better
value for money over time.
Answer Five: Yes, blue is acceptable as the school is gradually moving away from the
corporate burgundy and introducing new colours in carpets and the fascia of Block 4. I feel
the blue would suit the environment.
EVALUATION IN RESPONSE
TO CLIENT FEEDBACK
9457PAGE THIRTY FOUR
“I am extremely pleased with the final product
which is extremely appealing and would suit this
I am pleased that my client found then end product
aesthetically pleasing, however the majority of
materials I used were brand new and not recycled
as I had initially aimed for. Although I was able to
use primarily recyclable materials, such as the
Acrylic and Polypropylene as well as some reused
elements (the uPVC tube) in an improved version I
would source more eco friendly, recycled supplies.
“He has taken our school population into
consideration and designed a product which is
durable enough to survive in a school with a
population of 1000 adolescents.”
Despite my client praising the strength and
durability of my final product, I was actually not as
pleased with it as her, believing it could be made
stronger. Because of the materials I was limited to
due to limitations of the cost my final prototype, it
succeeded in being a scale model, however it was
not structurally the same as it would have to be for
the full sized working product.
“Value for money is extremely important. I
would compromise on quality if necessary, we
often have to. However, I would need a
product which lasts and so would be keen to
discuss longevity with Adam. I would pay more
if he could prove this would be better value for
money over time.”
I agree with my clients response to this
question, as I too believe that although the
initial price of the product is important, the
durability and longevity are more important in
the long run, therefore a compromise of
cheaper materials should be avoided for a one
off product such as this, whereas if the product
was to be mass produced, cheaper materials
should be considered which would be more
suitable for industry.
“I do believe larger rotor blades would be useful if
the product was larger.”
As I had initially planned, my client agrees that the
rotor section would be more efficient an well suited
being .25% larger.
“Yes, blue is acceptable as the school is
gradually moving away from the corporate
burgundy and introducing new colours in
carpets and the fascia of Block 4. I feel the
blue would suit the environment.”
I am pleased that my client is happy with the
final colour selection of light blues, which I
hoped would then blend into the sky on a clear
day, reducing visual disturbances often
attributed with lighting. I felt this was more
suitable that the burgundy colour scheme the
school currently has, especially as they are
aiming to move away from the burgundy.
Information about climate change . http://www.nef.org.uk/knowledge-hub/climate-change-energy/climate-
Information about VAWT’s. http://makezine.com/projects/wind-lantern/
Website from where I purchased the ball bearings for my product. http://simplybearings.co.uk/shop/Bearings-
Website from where I purchased the Acrylic rods and Polypropylene sheet. http://www.hindleys.com/index.php/materials/plastics-foam/sheet.html
Website from where I purchased the blue Acrylic sheet. http://www.trentplastics.co.uk/2012/
Website from where I purchased the 12v battery. http://www.cts-direct.net/power-sonic-ps1270-12v-7ah-rechargeable-sla-
Company who laser cut the Stainless steel sections. http://www.bristolmaid.com/
9457PAGE THIRTY FIVE