This paper provides an overview and appraisal of the International Design Engineering Annual (IDEA) challenge - a virtually hosted design hackathon run with the aim of generating a design research dataset that can provide insights into design activities at virtually hosted hackathons. The resulting dataset consists of 200+ prototypes with over 1300 connections providing insights into the products, processes and people involved in the design process. The paper also provides recommendations for future deployments of virtual hackathons for design research.
Paralympic rowers with functional impairments of the legs and trunk rely on appropriate seat configurations for performance. We compared performance, physiology, and biomechanics of an elite Paralympic rower competing in the PR1 class during ergometer rowing in a seat with three different seat and backrest inclination configurations. Unlike able-bodied rowers, PR1 rowers are required to use a seat with a backrest. For this study, we examined the following seat/backrest configurations: conA: 7.5°/25°, conB: 0°/25°, and conC: 0°/5° (usually used by the participant). All data was collected on a single day, i.e., in each configuration, one 4-min submaximal (100 W) and one maximal (all-out) stage was performed. The rowing ergometer provided the average power and (virtual) distance of each stage, while motion capture provided kinematic data, a load cell measured the force exerted on the ergometer chain, and an ergospirometer measured oxygen uptake (V˙O2). Where appropriate, a Friedman's test with post-hoc comparisons performed with Wilcoxon signed-ranked tests identified differences between the configurations. Despite similar distances covered during the submaximal intensity (conA: 793, conB: 793, conC: 787 m), the peak force was lower in conC (conA: 509, conB: 458, conC: 312 N) while the stroke rate (conA: 27 conB: 31, conC: 49 strokes·min−1) and V˙O2 (conA: 34.4, conB: 35.4, conC: 39.6 mL·kg−1·min−1) were higher. During the maximal stage, the virtual distances were 7–9% longer in conA and conB, with higher peak forces (conA: 934 m, 408 N, conB: 918 m, 418 N, conC: 856 m, 331 N), and lower stroke rates (conA: 51, conB: 54, conC: 56 strokes·min−1), though there was no difference in V˙O2peak (~47 ml−1·kg−1·min−1). At both intensities, trunk range of motion was significantly larger in configurations conA and conB. Although fatigue may have accumulated during the test day, this study showed that a more inclined seat and backrest during ergometer rowing improved the performance of a successful Paralympic PR1 rower. The considerable increase in ergometer rowing performance in one of the top Paralympic rowers in the world is astonishing and highlights the importance of designing equipment that can be adjusted to match the individual needs of Paralympic athletes.
To print high-performance polymers, a stable running printer that can reach high temperatures is needed. There is currently a lack of low-cost solutions that allow manipulation of process parameters and expansion of sensors to monitor the printer as well as the process. This paper presents an open-source hardware upgrade for low-cost 3D printers to enable research on new high-temperature polymers as well as manufacturing from all currently available polymers. The hardware cost less than $1700, including the printer. Opensource firmware by Klipper and Fluidd is used for control. The printer is able to reach 500 °C nozzle, 200 °C heated bed, and 135 °C heated chamber with all electronics inside operating within the recommended temperature range. The presented design produced a CF-PEEK 3DBenchy and a spiral vase with excellent surface quality and no signs of delamination. Test specimens according to ISO527 using PA-CF performed similarly to the datasheet provided by the manufacturer for samples produced in the XY-orientation and outperformed the datasheet by 15 % in the ZX direction. Compared to specimens made on an Original Prusa i3 MK3S, the modified printer produced specimens with 22% higher strength in the YX-direction and 25% in ZX. By continuously monitoring and carefully calibrating both hardware and firmware, the presented design can perform as a research tool in material science and produce large-scale components of high-performance polymers.
The current limitations of design for additive manufacturing (DfAM) are the state of knowledge on materials and the effects of production parameters. As more engineering-grade polymers become available for fused filament fabrication (FFF), the designs and processes must be adapted to fully utilize the structural properties of such materials. By studying and comparing the production parameters of a material test specimen and a component, the effects of layer temperature on the strength, surface roughness, and dimensional accuracy of PA6-CF were found. As the cross-section increases in component manufacturing, maintaining the layer temperature becomes a major challenge. From the findings, the concept of thermal layer design (TLD) was introduced as a way of increasing strength via temperature in selected regions after presenting the effect of layer temperature. TLD proved to have a major effect on layer temperature and heat distribution. Depending on the investigated layer temperature, from 147 °C to 193 °C the UTS of PA6-CF increased from 42 MPa to 73 MPa. Implementing TLD in DfAM represents a big leap for designing high-performance polymer components.
This paper presents an exploratory case study where video-based pose estimation is used to analyse human motion to support data-driven design. It provides two example use cases related to design. Results are compared to ground truth measurements showing high correlation for the estimated pose, with an RMSE of 65.5 mm. The paper exemplifies how design projects can benefit from a simple, flexible, and cost-effective approach to capture human-object interactions. This also entails the possibility of implementing interaction and body capturing in the earliest stages of design, at minimal effort.
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