During my experience at Metalbottoni I have been employed for research and development of new or improved products, connecting the in-house R&D department and co-designing directly with clients. This is an example of the process for the design of new aluminium accessories showcasing the company's explorative approach and knowhow.
Alessandro Valli
2022
Metalbottoni s.p.a - copyright© metalbottoni 2024
Adjustable hook (G-HOOK) for sportswear
The hook will have to be comfortable to hook and unhook quickly tapes, used as an accessory for backpacks or sportswear and urbanwear items.
Concept and sketches
User-centre approach: Functionality and Ergonomics
The shape has been identified merging functionality, ergonomy and technical requirements. Tensile strength calculations have determined the initial section and overall size of the hook.
3D modeling
Iterative Process
Prototyping
An iterative design process has been adopted, preparing adjusted cycles of prototyping and testing. Various in-house prototyping techniques have been used, testing different materials: resin additive manufacturing for shape models and further on zamak using silicon moulds, and eventually milled aluminium.
Iteration 1-3:
3D-printed resin prototypes
Iteration 4-5:
Casted Zamak prototypes with silicon moulds.
Final Concept
Improved resistance, weight and ergonomics.
The final concept, based on iteration n°5, results not only higher tensile strength but also half of the weight, using the same material. The outline curves have been modified to improve the hold and adjustability of the hook.
Tensile testing
One of the main requirements was the tensile strength of the hook, so multiple tests were conducted followed by design adjustments to reach a resistance of >40kg. A vertical press with a dynamometer has been used to test different shapes and materials. The iteration n°3 recorded an average resistance of 30kg while the iteration n°5 recorded an average of 50kg, both made of casted zamak. Five tests for each iteration have been conducted.
Communication
Printed folder
The project has been presented with a set of aluminium accessories, suitable for sportswear and urbanwear.
