One handy tool for prototyping is a laser cutter. At Salient, we use our laser to cut wood, plastic, cardboard and fabric for testing, prototypes and golden samples. However, with Halloween upon us, why not make a cardboard Birdman costume using the laser cutter?! Once you have a pattern, the laser cutter is more precise, repeatable and faster than cutting with a blade.
Here are some basic steps and images of the process. For full instructions, you can visit http://www.instructables.com/id/Cardboard-Bird-Man-Costume-With-Wings/
- Design the flat pattern in SolidWorks keeping in mind the ideal size and articulation for the wings. (This was very fast, allowing for the quick scaling of parts and patterning of features like feathers.)
- Cut out the pieces using the laser…. So much faster and accurate then cutting cardboard with a knife!
- Assemble the pieces using industrial strength hot glue, bolts and nuts for the wings and Gorilla Tape.
And, Voila! It’s a Birdman Halloween!
Extra-Special Overalls
Fly fishing is popular here in Bozeman, MT… Children named Madison sit in most elementary classrooms. Summer sees the university students (some called Madison) from Montana State (aka Trout U) disembark for their break as anglers far-and-wide school to the trout-rich waters of the Missouri watershed. Toyota pickups haul drift-boats and dressed-down business magnates on guided pilgrimages to the Madison, Missouri, and Yellowstone…. while scruffy locals haul their Toyota pickups to favorite streams. The “intellectual capital” of a good piece of water– those glorious little capillaries where God Himself surely smiles on the solidarity and good bite that greets the invested angler– is worth as much to the visitors as the gold that brought Western man to Southwest Montana 150 years ago; and even more to the people that live here year-round.
I fish. I like it.
For years, I wet-waded from March through October. At 6’7″ and 180 lbs, manufactured fishing waders have never been an option. I have a 37″ inseam and 33″ waist, and the price to slide into a pair of those extra-special overalls seemED (emphasis on past tense) a little too “extra-“ for me.
It’s an entirely different blog post for another time, but modern garment grading (the process that creates the various sizes of a garment; usually S, M, L, XL in sportswear) fails to fit a conspicuous portion of the market: tall/slim builds; long arms; small waist/large thighs; petite women; large busts. It’s not anyone’s fault, that’s the status quo— a necessary evil to enjoy the quality and level of detail in a state-of-the-art piece of clothing—or is it?… But again, it’s a different bite of the elephant than we’ll take today.
So what to do? Like any reasonable person, I decided to make a pair.
I’ll admit, I am critical of the state of design for fishing waders. The level of detail shown – especially in construction – in some of the alpinism kits hasn’t transferred to the fishing market. The clean aesthetic that bonding technology can provide are not only hyper-modern, but more efficient for applications requiring waterproofness, avoiding material stack-up, registration, and if you pick your battles, labor. I aimed to make a rendition of wader design that centered around being “sleek”—low fuss, elegant, non-decorative. Truth be told, my everyday dress is quite “square”—I like traditional cuts and traditional aesthetics, but I wanted to make something unlike what anyone has seen…. Spoiler: it 80% worked.
Keep in mind: the full design and fabrication of these waders were on my own time after-hours over the winter season, and had only a single iteration in full-on waterproof breathable fabric, that is: the final iteration.
You can see from the process photographs that the first patterns were mocked up out of my favorite WPB substitute: painter’s plastic—wonderfully stable, with a hand similar to most 3-layer WPB, and CHEAP. It took nine iterations of pattern prototypes to block and then cut a final pattern that I was comfortable moving into the final fabric/construction with. As it came together, it fit as I expected. I chose to go stockingfoot on this pair—what I hadn’t foreseen, nor could try in the plastic prototypes, was how installing the neoprene booties would change the fit; constraining the lower leg. For all my “clever” patterning—the darts, billows, ease, and gussets—and prototyping, there were still factors I did not imagine that manifested themselves in the designed material.
Quick plug: this is where Salient design process thrives—material testing and R&D to work out process, material, and technical construction issues: chemical compatibility, patterning, material choice, cost reduction. We complete our work on-site, and in good time, getting answers from our studio/lab/shop to our clients faster and more clearly than a factory may.
I used the waders all year long with no failures: high, cold water in the springtime Missouri, low small-stream fishing, floating on the bitterly cold Big Hole, and finger-freezing brown trout runs. I see their value, and I know the amount of work that goes into them… fishing waders are a lovely piece of kit, and I am happy to have them now.
That lower leg, though… I might have to make a revised pair….
Seth Carlstrom is the head of the Soft Goods department at Salient. He has a degree in Mechanical Engineering from “Trout U”, textile certification from NC State, and was producing performance garments and gear to fit his lanky frame long before being introduced to industry.
Process Practice Makes It Perfect
If you want to be good at basketball, it’s likely you’d spend hours dribbling, working on your layups, and shooting three pointers. Chances are, you wouldn’t go out to play only on Game Day when it’s all on the line, and hope for the best. Personally I’m not much of a ball-sports guy, but the analogy works.
Here at the Salient Soft Goods Department, we stay pretty busy with client projects on a daily basis, but unfortunately, much of that work cannot be shared with the public. Many of the staff members, including myself, still try to make time to keep our skills sharp through continued practice in personal projects. My most recent project is a classic soft goods item: the backpack. Here are some of the individual steps – lets walk through them together.
1. 
Defining a set of goals, styles, influences and attributes is a great place to start. These items can really help inform the projects direction, feel, and vision; and they can be used as a benchmark for individual questions and construction details later on.
2. A mood board or inspiration sheet allows you to examine different industries, specific materials, and any other items you might feel compelled to draw creativity from.
3. Sketch, sketch, sketch! I chose to focus on angular planes and shapes with rounded aspects dispersed throughout.
4. Define the basic dimensions. This can be done with paper/cardboard or computer programs – if you have access and knowledge.
5. Illustrate, define panels and construction details, pattern, and prepare to start fabrication. Alignment notches are your friends – use them! Patterning is an art in and of itself.
6. Gather materials and hardware. Local sources will have some items and can be a good start point, however, unless you have access to a specialty retailer, the internet might be the easiest place to purchase more technically oriented materials.
7. Cut and prepare materials. Laser cutters are amazingly accurate and fast tools, but good ol’ scissors have served well for many years prior to fancy, modern equipment.
8. Work backwards. Some seams and operations need to be done before others, and there is often a defined sequence that needs to be considered and worked through before sewing can begin.
9. Build. If individual panels or areas did not go as anticipated, they can be rebuilt – you might not need to finish the whole project first. And depending on the situation, you can learn more and push the project forward by learning from your mistakes. Few seams cannot be undone with a seam ripper (even if it is annoying and a step backward).
10. Use the result of all your hard work. First hand observation and testing is the best way to evaluate the overall effectiveness. Is it a good solution to the problem or goal? Evaluate the outcome – the good and bad; what went well, what was tough, what could go better next time – and improve on those aspects!
Document the final results and the process, for yourself and for others. Experiment, modify, and ultimately have fun! Sewing and the world of soft goods is a unique set of skills and knowledge, but the more you practice, the better and quicker projects will move along. Thanks for reading!
-Kirk Turner
Kirk Turner is an Industrial Designer, and has been bringing his brand of expertise to the Salient Team since 2015.
8 Reasons Getting Outside Makes You a More Creative Design Thinker
As a design and engineering consultancy, we feel living in Montana gives Salient a huge advantage in the realm of creativity and creative problem solving. It’s true that inspiration can be found just about anywhere – from backpacks dreamt up on mountain tops, to buildings modeled after crumpled up pieces of paper. However, we believe our energy and insight in the design world is fueled in part by gearing up, getting out, being immersed in and inspired by the details, forms, and colors of the wild, wide-open spaces that make this state so special. Not to mention the amount of hands-on testing and experimenting we get to do in this vast playground we call home!
In addition to funding personal projects with “Salient Initiatives” – which allow us to explore our curiosities in design – Salient offers many opportunities to employees that encourage us to get out and play in powder, take camping trips, and travel the world.
The following are just a few reasons we believe exploring and being active in the outdoors makes you a better design thinker:
Persistence: Try and fail, and try again
The tenant of Persistence is common in all outdoor recreations. As a first time ice climber, tackling the flows with Salient teammates this winter revealed muscles untrained, technique unrefined, and expectations that may not have matched reality. But failing fast, compelling forward, and trying until I physically couldn’t any longer are certainly traits I feel confident about bringing into my creative flow.
Noticing the Unnoticed: Taking time to slow down and zoom in (or out!)
Rock climbing is a big recreational activity for many at our office. As with many outdoor activities, while climbing you are 100 percent engaged, and focused on successfully sticking that next move – tackling one problem at a time. This focus, can bring a unique perspective, as you’re close enough to notice the things that remain unnoticed from a distance, like interestingly shaped pockets, colors, textures, and forms. Being on the rock promotes noticing these things in a different light than if one were to pass the whole rock face on a hike, or zip by on a bike – and can be truly eye-opening. Not only is this perspective inspiring as a designer, it also expands how I view these beautiful elements of nature. In good design, the simple, elegant, sometimes unnoticed details are the things that create a cohesive and complete product. If we can bring the practice of noticing the unnoticed into everyday life, it will surely bring a wealth of inspiration and perspective with it.
Simplify: Less is more
One of the first things we learn as designers is “less is more”! The “Simplify” concept translates seamlessly into lessons learned in the backcountry: bring less stuff. Not only will your outdoor experience be enhanced by forcing you to take in and use your surroundings, it will surely lighten up your pack, creating a more enjoyable hike to your destination. So, embrace the white space, use less text and fewer design elements for greater design-impact. A simpler, more focused, and intentional design often motivates better audience reaction.
Take Risks: Be daring!
Dare to think outside the box, and take the trail less traveled! The feeling while moving into the unknown isn’t always one that’s comfortable, there is often a sense unnerving shivers that flow throughout, and your mind almost always tries to talk you out of it. But taking conservative risks – in design as in adventure – will undoubtedly create a compelling experience that achieves the style-goal set and launches you into a feeling of pure bliss that leaves you wanting more. Rules and process are not absolute in design, but guidelines are there to get you started. Don’t be afraid to occasionally step off trail (when it’s smart), and take risks with your design, and creative thought process.
Propel your Practice: Human Powered
Most activities that are done here in the mountains are human powered. Whether skinning up a mountain to “earn your turns”, or placing cams to make your way up a gnarly crack on the side of a mountain to absorb the view from the top – you’re actively working for a result. The lesson of active work propelling my practice into success is one I find incredibly rewarding. Working hard, setting goals, and practicing your craft relentlessly will not only make you a stronger, faster designer, it will lead you to the level of refinement in your craft you strive for, and earn you the confidence to crush your goals in design, life, and adventuring.
Refresh: Make room in your mind from all of the confining details of everyday life
More room for creativity! Ever feel a little foggy after an average day plowing through your routine? The cure is raising that heartbeat, a bit of fresh air, or a sunset atop the highest point in town. I guarantee it. Gearing up, and getting outside makes you happier – It’s science! When you find yourself in a rut, to fuel your creative workflow sometimes all you need is a playful perspective. The fresh air and views create a great mindset for working through design problems. And when your mind is clear and refreshed, creativity has room to breathe, stretch, and settle into your next thoughtful design.
Turn Problems into Solutions: A positive and optimistic outlook is transformative
While venturing into unknown territory to in this case climb, surely has its benefits, it also means sometimes you get your vehicle stuck in the Kentucky backwoods and don’t have service to call for help… So rather than focusing on the problem at hand, and how unfortunate the situation happens to be. It’s helpful to get creative, stay positive, and makeshift a solution with the items you do have (sticks, debris, your own car mats) to get yourself out of there! The same is useful in design thinking, for example when designing furniture, sometimes toothpicks, popsicle sticks and tape can be your best friends to work through those tricky problems that arise as you try to move beyond the 2D form.
Biomimicry: Inspiration in Nature
“Biomimicry is an approach to innovation that seeks sustainable solutions to human challenges by emulating nature’s time-tested patterns and strategies. The goal is to create products, processes, and policies—new ways of living—that are well-adapted to life on earth over the long haul.” -the Biomimicry Institute
Nature often has solutions to problems present to humans that we have never even thought of, yet they have existed for years. A common approach to implementing these solutions into current products is to observe nature and its patterns, then sketch and develop based on the properties of these natural occurrences.
I know not everyone has national parks and mountain tops in their backyard, but just getting out to the park, the pond, the forest preserve, or your own back patio can make a big difference in your creative design thinking. So, now that you know how to channel these unique experiences into your creative process, I challenge you to find your adventure, get outside and expand your design thinking tool box!
Rebecca Allison is an Industrial Designer at Salient Technologies, Inc. She has a passion for the outdoors and soft goods design. In her spare time, Becca can be found adventuring in the mountains, or dreaming up footwear she’d like to make some day.
Innovation During a Pandemic
When the effects of COVID-19 began causing a shortage of personal protective equipment in America and Montana, Salient was quick to respond with design expertise. Salient designed an injection molded mask filter cartridge that is compatible with the standard 3M 6000 series masks to be mass produced in Montana. The team designed the mask in 3D CAD and then they 3D printed prototypes, which take about four hours each to 3D print. However, with injection molding, one filter cartridge can be produced in less than 60 seconds allowing for quick supply.
With a standard mask filter cartridge, it is difficult to sterilize the filter material inside. These cartridges must be thrown away. Salient designed a cartridge that easily opens by hand and snaps closed on all four sides. The N95-equivalent filter material can then be replaced or sterilized and reused. Salient’s previous experience designing many other various products allowed the Salient team to quickly respond and design a needed cartridge.
Salient is proud to collaborate with many other Montana entities in the effort to respond to COVID-19. As one of several companies that raised their hand to collaborate through the Montana Manufacturing Extension Center COVID-19 rapid response task force, Salient was appointed to oversee the design of the bayonet mount filter cartridges and compatible mask to ensure a quick and standardized response. Several injection molding shops around the state have expressed interest and are ready and willing to manufacture personal protective equipment for the state and beyond. Montana Tech is currently conducting testing on the Salient-designed filter cartridges to help validate the airflow as it moves through the certification process bringing it closer to full production.
Prototype Design: The Mechanical Development Process (in a Nutshell), Part 2
In our last post, we explored Stage 1 of the Mechanical Development Process – the Conceptual Stage. In this post, we’ll explore Part 2 of 3, the Prototype Stage!
Prototype Stage: Once a plausible direction is determined by the conceptual stage, the prototype process can begin. The prototype stage is often repetitious as products evolve and develop. Prototypes are essential to validating a concept since they allow designers to test, feel, hold, use and experience the product in a way that a simple sketch or rendering cannot. It is wise to keep in mind the end goal of manufacturing when designing for a prototype to help narrow down materials and manufacturing processes. Often, prototypes are created as a “proof-of-concept” to validate form and functionality, and are also built as show-pieces to generate interest in a product. The prototype stage allows designers and inventors to catch flaws and visualize enhancements at a relatively early and inexpensive stage. Inventors stand a much better chance at generating interest in an idea if a concept is proven through the prototype stage rather than just a conceptual sketch.
The intricacy and cost of prototypes may vary greatly, but even an inexpensive prototype made from clay and cardboard can validate a concept. However, in order to validate a design a more sophisticated approach may be needed. More intricate prototypes can come from designs modeled in 3D CAD as a virtual prototype, then rapid prototyped (3D printed) and finished to represent a final product. Higher quality prototypes are essential for trade shows, marketing and confirmation of a concept prior to moving into the production stage. Taking a solid idea this far is a strong position for the independent inventor looking to license the product. Prior to production, companies will often make changes to a design, so unless the inventor is the one manufacturing and distributing the product, it makes sense to hold off on investing beyond the prototype stage.
Check out the final part of this series, the Production Stage!
David Yakos is the VP, Director Creativity at Salient Technologies, Inc.
