As an open-minded and adaptable industrial designer, I thrive on tackling diverse projects that challenge conventional approaches. My experience at Loughborough has deepened my passion for exploring different perspectives, driving innovation, and embracing new ways of thinking in design.
X-TEND cuffs – major project
This project investigated into the problems associated with police handcuffs. After speaking with police officers, it became evident that handcuffing larger individuals behind their backs is challenging, often requiring the use of two linked handcuffs. However, this practice poses a safety risk, as linked cuffs can be weaponized against officers. Research also shows that detainees frequently suffer injuries from handcuffs, particularly during non-compliant arrests. While bruises and lacerations are common, more serious injuries like permanent radial nerve damage occur surprisingly often, with even minimal force from the cuffs causing severe harm.
For my major project, I developed a solution that highlighted the importance of prototyping. The initial concept involved deployable inflatable wrist protection, but testing revealed that it wouldn’t meet officers’ needs in the field. This led to the development of a more practical and effective solution.
Details of the final design can be found below:
The proposed design features extendable handcuffs that enable officers to securely ‘back cuff’ larger, non-compliant individuals, enhancing officer safety. These cuffs extend from a compact 290mm, suitable for everyday use, to 368mm in under 2 seconds with one hand, ensuring ease of use during high-intensity arrests. The cuffs are constructed from lightweight aluminium alloy, utilising die-casting for complex shapes, while the swing lock arms are made from high-strength stainless steel through metal injection moulding (MIM). The body is coated with durable, corrosion-resistant PTFE, ensuring reliability, easy cleaning, and resistance to wear and tear.
X-TEND cuffs are compatible with standard UK police keys and retain the proven double-lock mechanism to prevent overtightening. User testing and feedback showed that a single, easily accessible release and retract button is more effective than the initial plan for separate controls.
The protective coating can come in a variety of colours however it was crucial that a discreet all black option is available for low profile jobs within the police force.
A soft, durable TPU cushion can be integrated into the wrist restraints to protect the radial nerve in ‘front stack,’ ‘rear cuffing,’ or ‘rear stacking’ positions. This cushion is easy to clean, replaceable, recyclable, and cost-effective.
Due to limited access to the final materials, strength testing couldn’t be conducted. Instead, materials for critical internal components were meticulously evaluated and selected for their high-strength properties. The extension bar and stopper are made from high-strength stainless steel to ensure durability for repeated uses.
This storyboard illustrates how an officer can apply and extend the handcuffs one-handed while maintaining a firm grip and control over the suspect. To ensure correct use, one restraint is coloured differently, indicating it should be applied first for one-handed operation. User testing revealed that without this visual cue, officers might inadvertently use the cuffs incorrectly, requiring two hands.
Advanced CAD
During this module, I designed a new RC car controller using advanced surfacing and assembly techniques, culminating in high-quality renders to communicate the design. This module has significantly enhanced my skills in surfacing, which I believe will greatly benefit my future career.
In this module, I learned and applied Class-A surfacing techniques to create a concept suitable for injection moulding. Achieving minimum G2 surface continuity demanded multiple iterations, which significantly enhanced my surfacing skills and patience! The second phase focused on dividing the surface model into separate components for assembly, ensuring each part met injection moulding requirements such as draft angles, uniform wall thickness, and minimising undercuts. Below are some of the rendering views used to communicate the final design:
Main product views
In context render
Exploded view
Colourways
Joystick focus depth of field
Cutaway view
VISAR
VISAR is an augmented reality (AR) headset designed for urban search and rescue (SAR) operations, enhancing communication and coordination between SAR teams and their base of operations (B.O.O). Compatible with most SAR helmets, VISAR enables the B.O.O to send points of interest directly to the team, displaying their locations on the AR interface. The headset also allows users to quickly send their own points of interest back to the B.O.O using an intuitive dial scroller, resulting in faster, more accurate, and seamless communication during critical missions.
Given the limited time frame of this project, it was not feasible to develop and test a fully functional AR prototype. Therefore, the focus was on deeply understanding the needs and challenges of the end-users, in this case, an urban search and rescue team. One of the critical issues identified was the limited communication between ground team members and the Base of Operations (B.O.O), particularly in rural areas affected by disasters. The proposed AR headset is designed to significantly improve communication among team members by enabling rapid sharing of newly discovered points of interest. Importantly, the design ensures that the headset does not obstruct the user’s field of view during search operations. Additionally, it provides auditory alerts to guide team members in response to potential dangers, enhancing both safety and efficiency in the field.
This design aims to incorporate emerging technologies, such as AR mapping systems, to provide visual cues for points of interest directly within the headset. Additionally, Tesla’s Starlink, which has the potential to become portable, could be integrated into the headset to ensure a reliable connection with the B.O.O., even in remote or disaster-stricken areas.
The development sketches focused on how these features could be effectively utilised in high-intensity rescue situations, even while wearing heavy-duty gloves and other protective gear. Since team members’ hands will likely be occupied with rescue tasks, the challenge was to strike a balance between offering AR assistance and avoiding interference with their work.
PROSTHECO trans-radial orthotic brace
The Jairos Jiri Association (JJA) is a charitable organisation in Zimbabwe that provides prosthetics to amputees. However, the current solution is costly, with each prosthetic costing around £4,000, and the organisation is only able to assist approximately 250 people annually, falling far short of the growing demand.
In response, our group was tasked with creating a business to offer a more accessible solution for amputees in Zimbabwe.
As a group, we founded Prostheco, a community interest company focused on providing orthotic braces for upper-limb trans-radial amputees. Our design utilises locally sourced materials and partners with local businesses to manufacture the braces. This new solution eliminates the need for lengthy fittings and features a custom-coloured sleeve, addressing the social stigma that amputees often face.
Our target consumers are adults aged 16 and older with trans-radial amputations, often resulting from work-related incidents or traffic accidents. Many of these individuals, especially those in rural areas, face challenges in maintaining their independence. The brace is designed to support lifting up to 20 kg and features a body-powered pinch grip along with a durable hook, enabling users to perform a range of daily tasks with ease.
By partnering with local forgers, textile producers, and fastener manufacturers to create and assemble the product, we can ensure both affordability and high quality, all while supporting local businesses and strengthening the community economy.
