Product category:
Rapid Prototyping
News Release from: Martello | Subject: Rapid prototyping
Edited by the Engineeringtalk Editorial
Team on 06 October 2005
Rapid prototyping speeds innovation to
market
When David Alner devised a novel handle design that could make the humble wheelbarrow more controllable, he needed trial prototype models to interest prospective buyers.
Anyone who has ever had to move a wheelbarrow with a heavy load up a gangplank for unloading may well have experienced some discomfort and even tipped the barrow over the side before getting to the top This is just what happened to David Alner when he was moving some dirt into a skip using a scaffold board
However, he had an idea that would solve the problem.
He realised that it was the handles of the wheelbarrow that needed to be changed in order to give better leverage to the user.
Alner and a friend of his, Paul Blanchette, had some bull nose handles made, which they then experimented with while thinking about different concepts.
Alner settled on an idea that was aptly was called at the time Grip 'n' Spin - the product is now know as ez-tippa.
The handle swivels on bolts attached to the main arm of the wheelbarrow.
The handles literally "spins round" so that when you are using the wheelbarrow the handle can remain horizontal, ie your hand is not pulled out of alignment and you maintain balance and control of the barrow.
This benefits the user considerably when moving heavy loads up steep gangplanks due to the handles swivelling in the bolts.
The first models were aluminium blocks, which Alner then machined by hand to the initial concept.
They then showed to various manufactures hoping to attract investment.
However, the cost prohibited taking the idea any further so Alner decided to take the initiative and fund the manufacturing of the parts himself.
He needed trial prototype models to interest prospective buyers but he needed to be production quality parts.
The original idea was that they would license the handles to wheelbarrow manufacturers, but this evolved into actually selling the parts direct with the wheelbarrow.
However, he did not at this point have the free capital needed to commission an injection mould tool and needed to test the market with a few trial models first to gauge interest.
It was at this point Neil Campbell of BEC Tooling introduced Alner to Martello.
Martello's Engineering Manager, Dave Davis worked with Alner to finalise the design and produce the CAD data.
SLA models were then built on Martello's rapid prototyping machine and used to verify form fit and function before silicone rubber tools were commissioned to produce the plastic parts.
Several variations were produced in different colours and the design of the handle was sculpted to give more comfort to the user.
Alner was impressed by the fact that it is possible to create production quality parts without the cost of injection moulding.
He comments: "It was wonderful to find Martello and get production quality parts made so economically".
Alner then went onto to show the handles in action to interest various companies; intriguing one major DIY store chain by leaving a wheelbarrow with the handles fitted inside one of their stores.
The handles have recently been exhibited at the British Invention Show at Alexandra Palace with the full design to production story on view, including the silicone rubber moulds from which the first handles were produced.
So much interest has been created that Alner has now set up his own company - the Real Barrow Company (www.realbarrow.co.uk ) - and also teamed up with Fort Wheelbarrows to deliver the ez-tippa to market.
Companies and the public will be able to purchase the whole wheelbarrow (together with the handles) direct from the person who designed it.
Alner comments: "We've gone from one side of the chess board to the other".
• Martello: contact details and other news
• Email this article to a colleague
• Register for the free Engineeringtalk email newsletter
• Engineeringtalk Home Page
Search the Pro-Talk network of sites
