Creation
Manprit SIngh Nichal
To Make the front of the scooter I had to first cut out the correct-sized pieces of MDF, I did this by referring back to my dimensions page where I had planned all the sizes for each of the components of my scooter.
​
I cut out the front of the scooter first as this was the piece that needed to be Laser cut and took the longest.
​
I measured out the pieces for the front on the MDF and then printed a scale version of the design that needed to be laser-cut and temporarily stuck it onto the MDF to see if the dimensions on the file were correct before laser cutting.
Lazer Cutting
I then started to make the base of the scooter to get the thickness of the base I measured the thickness of the bottom and top pieces and subtracted that from the total thickness which was 5cm, I then made 3cm cubes which I used as spacers in between the two pieces to get the 5cm thickness for the base of the scooter.
​
to stick everything together I used PVA/Wood Glue to stick them together, I then clamped everything together to let the glue dry evenly.​​​
To finish the front of the scooter I made the edges of the front with MDF cut to size and then sanded down the edges to create the angle for the shape of the generators on the front.
​
I then stuck all the Inside pieces to the laser cut piece with PVA/Wood Glue, I then put the other laser cut piece on top of the inside walls using PVA again and then clamped it all together to ensure a great seal
​
once dried i cut and sanded the outer walls of the scooter and stuck them in using PVA, which I once again clamped and let dry.​
After making the front I moved on the the turning mechanism which I had designed using a maquette beforehand to ensure that it would function correctly and to figure out how I would integrate that mechanism into my scooter.
​
I made the turning axle out of a wooden dowel to allow the base of the scooter to turn freely with the front of the scooter.
​
To do this I drilled two holes in a piece of wood one side which would connect to the base of the scooter and the other side which would connect to the front of the scooter
during this time one of the sides unfortunately broke off due to the amount of stress put on it from the weight of the front of the scooter so to tackle this problem I removed the excess wood and replace the hole with a metal O Ring screw into the wood making the connection much stronger
After creating the mechanism for the turning I connected the front of the scooter to the base and tested out to see if the front would turn after testing I found out that it does turn but the scooter would not stand up on its own as there was not enough strength in connecting rod making it too weak for the scooter to stand on its own
​
To fix this solution I had to create a temporary stand for the front of the scooter to lean on making the scooter stand on its own
​
i made these supports using some wood which I cut and sanded to size at the right angle making the front able to rest on the base using the supports.
​​
the supports are not stuck to the front of the scooter allowing it to still be able to turn.
Turning Mechanism
After making the front and base of the scooter I moved on to making the tires for the scooter i made these by using a piece of plywood that I used to cut out circles from i created a circle on the plywood as a guide to cut them out using the bandsaw which I then sanded down using the belt sander to create a smooth surface.
​
I created two smaller circles for the back wheels and a larger wheel for the front wheel i then drilled a hole through the back of the base of the scooter to fit a wooden dowel through which I connected to the back wheels allowing them to spin freely.
​
For the front, I used a smaller length dowel which I cut to the precise side of the front part of the scooter I then pressure fit the dowel with the front wheel on with some PVA/Wood Glue making sure it stays in plays and doesn't move.
​
After adding the rear wheels I noticed the back of the base of the scooter was too sharp and kept hitting the floor so I got the base and sanded the bottom corner to make it round and allow the back of the scooter some space for the scooter to adjust to almost like the suspension height on a car.
To finish of the base I added a white border around the base of the scooter to make sure the wooden spacers in the base of the scooter were hidden,
​
to this, I initially decided to use a white piece of acrylic which would have been a better option visually and would have looked cleaner, but instead, I decided to use thin foam board I did this because foam board is considerably lighter than acrylic, reducing the weight of the scooter, this was important as the weight of the scooter was already heavier than expected so I decided to use the lighter option for materials throughout the build.
​
i also made a curved cut in the foam board next to the wheels to make them fit in with the build better rather than the foam board just cutting off sharply making it look tacky.
​
To finish the front of the scooter I made the handlebar which I made using a scrap piece of Copper Pipe which was the perfect dimensions of the handle, the color of the handle also fits in very well with the design aspect of Dyson, Copper is also very cheap and strong making it an amazing choice of material in production.
​
The copper pipe I found was a bit dirty so I cleaned it up I also decided to add some leather for where the hands would go as copper being a metal is a good conductor so when using it the handles would have become too cold to use so I found some scrap leather which I cut and glued onto the handlebar.
Evaluation
Technical Skills
For this project, I utilized a variety of techniques to create a self-sustainable E-scooter designed for Dyson. The scooter integrates advanced sustainability features, including front-mounted air purifiers that double as generators, solar panels on the base for charging, and an AC system integrated into the handle for dispensing purified hot or cold air. All functions are controlled via a swiveling touchscreen on the handlebar.
​
To construct the prototype, I used MDF as my primary material, cutting it with a laser cutter to ensure precise shapes for the design. I also experimented with other materials such as foam board and copper pipes. Despite limitations in using metals due to cutting restrictions, I worked around this by selecting lighter alternatives to maintain the scooter’s functionality while keeping the weight manageable. Additionally, I created maquettes to explore and test the turning mechanism and the overall design before committing to the final build.
A major technical challenge was ensuring that the designs created in Illustrator were to the correct scale. To address this, I printed the designs on A3 sheets before laser cutting, which allowed me to verify accuracy and make adjustments as needed.
Professional Practice
Time management and planning played critical roles throughout the project. I broke down the assignment into manageable steps, starting with creating scaled maquettes to test concepts. This allowed me to address any technical issues early, such as adjusting for material restrictions and maintaining the balance of the design.
Although I couldn’t use metals as intended, I researched alternative materials that provided similar visual and structural qualities. This required flexibility and creativity, ensuring that I could still meet the brief without compromising the design. I also took measures to minimize risk, including double-checking all measurements and weights to ensure stability and functionality.
Problem-Solving
Throughout the project, I encountered several challenges. The inability to use metals for key components was significant, but I overcame this by selecting lightweight alternatives such as foam board and MDF. Balancing the scooter’s weight was another concern, especially as the design incorporated multiple features like air purifiers and solar panels. Regular testing and adjustments allowed me to refine the design and maintain functionality.
Another challenge was ensuring the precision of the front designs in Illustrator. Printing the designs to scale on A3 sheets before laser cutting helped me verify dimensions and avoid costly errors. These iterative steps helped refine the outcome and saved time in the long run.
Communication
To communicate the design clearly, I created detailed maquettes and prototypes that visually represented the scooter’s features and mechanisms. The maquettes demonstrated the turning mechanism and overall form, which made it easier to present and explain the project’s functionality to others.
Additionally, I used annotations and sketches to document my process, ensuring that all changes and developments were communicated. This helped ensure the final outcome aligned with the original brief and client expectations.
Final Outcome and Reflection
The final design effectively met the brief, combining innovation and sustainability in line with Dyson’s brand ethos. The self-sustainable features, such as air purification, solar charging, and temperature-controlled AC, address environmental concerns and user comfort. The swiveling touchscreen further enhances usability and aligns with Dyson’s focus on cutting-edge technology.
Strengths of this project include my ability to adapt to challenges, such as material restrictions, and think creatively to find solutions. I also demonstrated strong technical skills in laser cutting and model-making, ensuring precision throughout the process.
However, one area for improvement is in planning and anticipating potential setbacks. While I was able to overcome issues, such as material limitations and scaling errors, more thorough planning at the outset could have saved time and reduced stress.
What I Learned
This project taught me the importance of adaptability and problem-solving. I learned that unexpected challenges are inevitable and require a flexible approach to resolve without compromising quality or timelines. Additionally, I now understand the value of precise planning and testing at every stage to avoid larger issues down the line.
In future projects, I will apply these lessons by improving my planning process, exploring alternative materials earlier, and continuing to test and refine concepts before finalizing designs. This will ensure I can deliver innovative and functional outcomes more efficiently.