Compass Design

Roadmap to success

Every product travels a journey.  From the initial idea, through product definition, refining the design and proving the concept to finally delivering a finished product to your customer.  For this journey to be successful, it is crucial to set a proper course and hit all the milestones.

At the beginning of the project, we’ll facilitate a project kick-off meeting to review and discuss the product goals, marketing targets including the corporate image, human factors for the product use, environmental requirements, regulatory agency approvals, material selection and manufacturing capabilities.  By understanding these key project elements it helps to insure your project doesn’t veer off course and arrives to your customer on budget, on schedule and on target.

What else would you expect from a company named Compass?

Nothing like first hand experience    

To get a better understanding of the project and the user’s experience, we watch, ask questions and listen to the product users or target audience.  We’ve been in numerous operating rooms, asked teenagers about acne products and filmed users trying to figure out how to clear a jam on a copier.  When possible, we roll up our sleeves, climb in and experience the product ourselves, as shown in the photo above.

Here, one of our designers is understanding the patient experience in the Imatron CT scanner.  Body scanners can create feelings of claustrophobia in some patients and we wanted to get first hand knowledge.  By getting on the patient table and going through the motions of a scan, the designer can see for herself what we could do to help minimize that sensation.

Know the enemy

It’s important to know the competition. Our staff will study what they are doing, how they implemented their solutions, and use that information to position our client’s product in the market. We look at the competitive products through the eyes of the target consumers by using the competitor’s product when possible. We research through traditional as well as online media sources.

Diverge to converge

The goal of a brainstorming session is to generate, nurture and build on as many ideas as possible in a condensed time.  To accomplish that, we bring together a diverse group of contributors – designers, engineers, human factors specialists, users, clients – and have them tackle the problem.  We try to come up with as many possible solutions to the problem as we can and capture those ideas in quick sketches.  The sketches are displayed for everyone to see and participants are encouraged to build on the ideas they see.  The outcome is a wealth of new and creative problem solutions in a short time span. 

Who are these people?

Who is going to use the product?  What are they like?  What is important to them?  These are some of the questions we ask when starting a new project.  We want to intimately know who the customer is so we can craft the best product solution to meet their needs.  

And the customer is not just that person who buys the product at the store.  It may also include the service technician, the assembly person on the manufacturing floor and the marketing professional who is charged with selling the product.

For each “customer” we create a user profile that personifies their personal attributes such as likes, needs, capabilities and technical awareness.  The staff then uses these profiles throughout the process to help judge their design solutions as the project moves forward.

Sketch this

Most of our designers grew up sketching with a pencil and paper and it’s still the best way to quickly capture product concept ideas.  No other medium gives the designer the speed and freedom to explore ideas better than sketching.  For some projects, we will create hundreds of sketches looking at the form, colors, construction techniques and style before arriving at the final design. 

We still sketch with a pencil and paper.  And to keep up with the latest technology, we now also use tablet PCs with Alias Sketchbook Pro software, which allows the designer to draw directly on the computer screen, a “new school” approach to a traditional skill.

The connection between the product and the user

The term human factors encompasses a variety of man to machine interface elements. Some of the work is physical where we craft the design to fit the users body size, kinematic capabilities and strength. Other work deals with the cognitive ability of the user to understand how to use a product, user interface design and menus. And finally there is organizational design where the product and the entire work structure is studied and optimized.

In the example shown above, we’re setting the anthropometic parameters for a medication delivery cart design project.

3D sketching for the design staff

We like models.  Our staff thinks of them as 3D sketches, a way to work out the forms and shapes for a new design with their hands.  Sometimes they’re rough, maybe even crude to quickly evaluate a design direction.  This way in a matter of hours or a few days we can review the design and use the information to keep the project moving.  This saves our client time and money.

At other times, like the urethane foam model above for a dermatology laser, they are more carefully finished as part of a later stage appearance presentation.

We make these models in one of our two, in-house model studios using foam core board, plastic and urethane modeling foams.

Looks like the real thing

Appearance models show the final appearance of the product before the production parts are ready.  They can be used in trade shows, marketing collateral and to show the product team the direction of the final design.  Some models we make in-house and others we use our development partners for a specific expertise.  Over the years we have made models that are small enough to fit into your mouth as well as large, full-scale capital equipment projects.

The OUR Medical model shown above was used extensively for trade shows.  Since the real product weighed 44,000 lbs. (yes, 22 tons!), this full size foam and fiberglass model was their only choice on the trade show floor.

Photorealistic imagery

Sometimes, a hand sketch isn’t polished enough and building a physical model takes just too much time or money – that’s where a computer rendering really shines.  Not only does the product image convey realistic textures and colors, but it can be placed into real life photo environments for focus groups and marketing feedback.

BodPod wanted to see their product before the tooling stage was started and they wanted to be able to show their customers the upcoming product.  The rendering shown above was done in PhotoWorks, an add-in module to SolidWorks.

Build it, try it

This is where the mechanical engineer starts to piece together the foundation for the product design. Parts are put together with tape, hot glue and clamps to quickly try a variety of configurations for the design.

The photo above is of a light source for laboratory equipment and the engineer is looking at the placement of the fan to cool the light source.

Dial it in

By the refinement phase we’ve got the basic configuration for the product and we’ve done enough development to start focusing in on the details of the design.  

A good example is the Nektar drug delivery device.  It uses a hand operated air pump to create air pressure for the device.  One of the challenges was to design a handle that was comfortable for a large hand as well as a small hand that could effectively be used by someone with weak hands.  We created the model shown above where we could attach different handle parts to try different designs before going to production.

No more pencil and paper

The mechanical engineering world revolves around the CAD system.  Where the engineer used to detail the final design on a drafting table with sheets of vellum and graphite pencils, it’s all on screen today.  We work in SolidWorks, ProENGINEER and Creo software packages.  

And we have some of the best engineers in the business.  We’ve won industry awards, been featured in CAD magazines and SolidWorks put one of our designs on their owner’s manual cover a few years ago. They’re good.

.

Pressure packed

For some projects, we conduct an analysis of the design before any parts are made.  In the example above, we used Nastran finite element analysis (FEA) software to investigate the loading on a vacuum lid design.  By putting the design through a simulated test like this, we can see if there are any areas where the part needs strengthening or where we can reduce the material and still achieve the desired results.

Test till you drop

For some mechanical devices and mechanisms, we put them through a battery of internal tests to see if the design can stand up to the requirements in the market.  

That spinning blur in the middle of the photo above is a cam surface that activates the handles on a surgical device as it spins around. This particular unit has the capacity to hold three devices so we can test more units in the same amount of time.

Finding a solution

Once the engineer has made a preliminary design on paper, the initial electronic concept design is often built up using either a breadboard or plug board as shown above.  This allows the electrical engineer the freedom to experiment easily while testing out the design.  A variety of electronic systems may be prototyped by using breadboards, from simple small circuits to entire CPUs.  Of course, complex circuits can become unmanageable on a breadboard due to the large amount of wiring necessary.  These more complex circuits are often “breadboarded” on the computer using simulation software.

Electronic CAD

Once the concept circuit has been proven the next step is to bring the design into the CAD program where it can be prepared for the prototype build. The preferred software is Protel DXP but the team also has experience in Mentor Graphics and Cadstar.

The window to the product

Software is what brings the product alive, gives it character and allows the user to interact with it.  The design of a user interface allows the user to provide input into the system and interpret output from the system.  To a large degree, it is a key element to the experience of using the product.

At Compass we use a collaborative approach to the user interface design bringing together human factors experts, graphic designers and the software code writers to work through the design and implementation of the interface.

Running them through their paces

All through the electronic design process we test, revise, and test again. Our internal lab has all the equipment necessary to evaluate the design and test the functionality before going to production.

Cut away

The start of the prototyping phase is to fabricate the parts of the design.  To do that, we utilize a variety of prototyping methods including CNC and hand machining, rapid prototyping directly from the CAD files, metal forming and welding, castings and various finishing techniques.  Where possible we use the same material as the production unit to give more realistic and repeatable test results.

In the photo above, the front bezel for the Reliant product is being machined.

Instant gratification

A few years ago we added a Dimension FDM (Fused Deposition Modeling) 3D printer to our in-house capabilities.  The advantage over a SLA type printer is the FDM process uses ABS plastic as the base material giving parts that are stronger and more resistent to warping and deforming in heat.  These parts are perfect to verify CAD data and can be finished as an appearance model.

We think there is a big advantage to having this printer at Compass.  We have complete control over the build, we can set our own priorities based on the client’s schedule and we can monitor the build remotely via the internet.  Another bonus – we can keep your project confidential.

The Dimension specifications are:

• Maximum build size per part is 8.00″ x 8.00″ x 12.00″ (200 x 200 x 300mm). We can combine parts to create larger models.
• The material is ABS engineering resin, various colors are available.

Try it out

At facilities in Northern Ireland we can fabricate prototype and limited production PCB assemblies.  Capabilities include; electroplated PCB fabrication, reflow SMT assembly, and various manual soldering stations.  PCBA testing is carried out using a range of in-circuit test equipment and functional test equipment.

Give it a fresh coat

We offer a variety of painting, graphics application and finishing options. We can apply paint finishes from smooth and glossy to rough and weathered.  In addition we can apply product graphics for a realistic appearance.

Put it all together

The final act of the prototype phase is to assemble the parts and test the entire design against the specifications.  Often this results in a short run of 3 to 9 sets of parts that are used in limited trials to gather feedback from real users.  In some cases these units are also used for regulatory agency submission.

In the photo above the technician is assembling the Reliant Fraxel laser system for clinical trials.  The covers for these prototypes are urethane castings with a sheet metal internal chassis.

Finding the best partner

The quoting and vendor selection process usually begins early in the project with Compass researching and identifying a short list of qualified partners, usually both domestic and offshore.  As the design files move through the process, we send quote packages for initial cost estimating as well as for feedback from the vendors to the Compass design team.  This dialogue with select partners helps to refine the design for efficient production capabilities and supplies the team with the latest cost, component availability and materials information.  That way we can help guide our client to the best decision for their unique needs.

The final touches

Getting the product designed, engineered and into production is our primary focus but we’re often asked to provide additional product support. To complete the journey we offer the following services:

• Logo design.
• Product graphics.
• User/Quick reference guides.
• Packaging.
• Trade show displays.

By coordinating the entire product visual experience, we can create a complete image for your product.

A complete package

Documentation of the design is the important, final step in the design process.  We provide full documentation, both 2D drawings and 3D CAD files for the mechanical parts and Gerber files for electronics and the code for software.  We also prepare a complete Bill of Materials for mechanical and electronic components.

Check it twice

First article inspection is our chance to check the tooled parts for the first time. Usually the vendor provides a first article report and we do our own checking of the part in-house. If needed, we may also send the part out for independent verification using one of our qualified suppliers.

We think that phrase captures our philosophy perfectly. We create designs that work.  They work in the market by being innovative, creative and unique.  They work for the customer by being easy to use, friendly and a positive experience.  And finally, they work on the manufacturing floor by being cost effective, timely and using appropriate materials and technology.

And we create brands that sell. It’s not enough to simply create a manufacturable design. the design must be compelling to the customer and entice them to choose one product over the other.  The competition in any market is tough, make sure you choose a firm that can help you win the battle.

That’s not a problem. We can tailor our services to just what you and your company needs.  We understand that not every client needs a complete development program and we’re happy to help those that just need a little help.

Our typical, full service project is broken into four primary phases; research, design, prototypes and finally, production.  The research/design phase is when we learn about your particular idea, research the market/users and develop the basic functional foundation for the product.  In the design phase, we build on the foundation with industrial design, mechanical and electronic engineering.  We build prototypes next, test them and refine the design as needed.  Finally we prep the product for production, manage the tooling process, conduct first article inspections and get the production line moving.

For the 2D design side, we use: Illustrator, Photoshop, Alias Sketchbook Pro and Vellum Graphite.  For the 3D engineering side, we use SolidWorks and ProEngineer/Creo as our primary platforms.  We also use PDMWorks for document control.

Yes, many of the projects we have on this site were brought to us by entrepreneurs.  Some projects are not a good fit for us but we’d be happy to talk with you. We’ll always give you straightforward advice.

We start with a conversation about your goals and how we may help you reach those goals.  It’s important that we feel comfortable with each other and our philosophies are in sync.  If everything is working out, we’ll prepare a proposal showing the plan for your project, deliverables, dependencies and schedule.

The first step is to get in touch with us. To get the ball rolling, give Curt Anderson a call, his direct line is 925/485-1071