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Junior design project
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About
Berg
Design problem
In Junior Studio, students were given the prompt to design and manufacture a unique style of belay device. The project scope was broad with little parameters or guidelines.
For this project, I chose to complete tasks using the fictional company Berg, which was exhibited in depth on the Apparel Design page.
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Market Examples
Black diamond pilot, Petzl grigri, Madrock aviator, Mammut smart, Edelrid mega jul, Petzl pirana
There are a plethora of belay and rappel device styles on the market, each one performing different tasks than the model before it. Some conduct assisted breaking for the user, while others are only used for simple procedures. Some have moving parts and certain ones are made out of a single piece. Being given a wide scope of options, I had the discretion of choosing which style to pursue.
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Inspiration
Sprue, Pouring cup, Riser, Cope, Gating system, Mold cavity, Core print, Drag
Sand casting
When choosing the style of belay device to focus development on, I started off by selecting a manufacturing method. That dictated which type of device could be produced in the first place.
I chose sand casting because class resources were available to implement an in-depth learning experience in that area. I also selected it because the outdoor industry hadn’t utilized that process very much. It would be the perfect design challenge.
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Iteration 1
Modeled after the Sterling Rope ATS Belay Device, this design was intended to provide a multi-tool experience. Theoretically, it could be used for a variety of belaying and rappelling styles.
Sterling Rope ATS Belay Device
Features
4 External hooks in convenient locations for friction points. Bottom hole for anchor point. 2 Oval holes for double rope rappel and other configurations. Large hole for speed rappel and complex rope configurations. Holes oriented in compact pattern to maximize functionality
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Iteration 2
Changes
Double rappel holes combined with anchor point to create new anchor point/belay hole. Width of neck brought in to provide space for rope in figure-8 configurations.
Notes
External hooks/friction points kept. Anchor point doubles as belay hole. More compact configuration. Large hole kept. Still functional for rappel, belay, and canyoneering use
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Iteration 3
Changes
Top horns widened to provide space for rope. Large hole revised from polygon to circle to match style of other components. Holes enlarged to fit most rope sizes. Wall thickness widened to resist greater stress
Notes
External hooks more accessible. Anchor point kept but enlarged. Larger size. Top hole with retained functionality and updated look. As always, functional for rappel, belay, and canyoneering use
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Final iteration
Changes
Bottom horns lowered to free up space around neck. Top horns brought in to protrude less. Large hole modified from circle to ellipse. Anchor point elongated for advanced belay performance
Notes
Optimal hook positioning. Refined anchor point. Refined top hole. Perpetually optimized for canyoneering, rappel, and belay use
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Prototyping stages
LOW FIDELITY MOCK-UP. FIRST ITERATION 3D PRINT. FINAL ITERATION 3D PRINT. LOOK AND FEEL
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Line drawing
Final dimensions
All CAD models for this project were completed on Fusion 360. I have used SolidWorks and Solid Edge in the past, but I have recently come to favor using Autodesk programs.
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Final prototype
Pattern and flask, Mold preparation, Cope and drag, Pouring, Big reveal, Rough casting, Finishing, Anodized, Finished product
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Last look
From idea to reality; being suspended from wall attached to a product I engineered and built felt really good.
