DULLES, VA. (Sept. 7, 3:55 p.m. ET) — Plastics were prominent in two-thirds of the gold winners of the 2011 International Design Excellence Awards.
A disposable sheet for patient transfer, a personalized limb prosthetic and a portable fire-rescue radio were among the winners.
The Industrial Designers Society of America in Dulles organizes the annual contest.
Davin Stowell, founder and CEO of Smart Design LLC in New York, chaired the 2011 panel, which had 20 design-oriented members. Panelists selected winners of 27 gold, 68 silver and 96 bronze awards from among 524 finalists. The competition received more than 2,000 entries from 39 countries.
Here are plastics-related highlights of the gold IDEA winners:
Medical technology firm Stryker Corp. of Kalamazoo, Mich., and film laminator CTI Industries Corp. of Lake Barrington, Ill., won a gold IDEA for the disposable Speed-Sheet device for transferring or repositioning a patient.
The transfer and fluid-barrier sheet lies inert under a patient at all times and transforms into a low-friction transfer aid when the patient is laterally transferred to another surface.
The multilayer custom-laminated polyethylene-nylon film construction has a varnish coating that mimics the surface characteristics of mattress properties on the top surface while adhering to the mattress during use.
Two sheets have outer and inner sides with the inner sides facing each other. Each outside has a high coefficient of friction, and each inside has a low coefficient and a lubricious polymer coating. The outer surfaces may have a rubber-based coating or a Saran-type PVC film layer.
The releasable sheets are coupled together to limit relative movement until the vacuum-pressure coupling is opened. A resealable opening allows more than one use of the device.
Stryker's emergency medical service department in Portage, Mich., and CTI Industries designed and customized materials, fabrication and embossing processes and the manufacturing equipment. Molding and production took place at CTI.
During 2010, Stryker obtained a U.S. patent on Jan. 26 and began Speed-Sheet commercial sales in June for about $10 per sheet.
Credits go to Stryker's Cliff Lambarth, Jeff Lewandowski, Marty Stryker, Jason Wroblewski, Jason Kneen, Andrew Faulkner and Vas Subramanian, and CTI's Rick Sherman and Rahul Deshmukh.
Product creator Bespoke Innovations Inc. of San Francisco won for an accessory that restores symmetry and natural contours to an amputee's body. The Fairings-brand custom-tailored leg cover includes parts with materials including polyamide and a property-changing photopolymer.
For most components, 3D Systems Corp. of Rock Hill, S.C., or other vendors use the selective-laser-sintering process for PA parts and a stereolithography-type solution with liquid-based photopolymers. The PA parts are curbside recyclable, dishwasher safe and fabricate easily.
After taking a three-dimensional scan of an amputee's surviving leg, Bespoke incorporates optional colors, materials and finishes into Fairings for a prosthetic limb, allowing for a personal connection.
Bespoke Innovations received a U.S. patent for the Fairings in early 2011. The firm shipped its first commercial product in September and has as many as 150 potential orders in the pipeline.
Bespoke Innovations' Scott Summit and Christopher Campbell receive credit.
Communications equipment provider Motorola Solutions Inc. of Schaumburg, Ill., won for design of the APX 7000XE P25 portable radio. The product is primarily developed at a facility in Plantation, Fla.
Polymer materials — some proprietary technologies — include an insert molded polycarbonate external housing and coextruded elastomer rotary knobs and rubber bumper system. The speaker grill and control-top bezel also contain plastics.
Introduced in August 2010, the mission-critical two-way radio is intended for the fire-rescue industry. Gloved hands can use an exaggerated control top. An enlarged top display permits at-a-glance viewing.
Credits go to the design innovation and design engineering teams of Motorola Solutions.
Lift-truck maker Crown Equipment Corp. of New Bremen, Ohio, and Design Central Inc. of Columbus, Ohio, won for design of the battery-powered Crown WT 3000 series pallet truck.
Thieme GmbH & Co. KG of Teningen, Germany, uses reaction injection molding to produce dashboard covers of impact-resistant Bayflex-brand elastomeric polyurethane.
Another Crown supplier blow molds the hydraulic oil-reservoir tank of nylon 6. JTEKT Corp. subsidiary JTEKT HPI SAS of Chennevières-sur-Marne, France, supplies an assembly that includes the reservoir tank, a motor and a breather filter.
A design and engineering team at Crown's European headquarters in Munich developed the pallet truck. The plastic parts are assembled on the truck at a Crown facility in Roding, Germany.
Crown introduced the WT 3000 in March 2010 with marketing now primarily in Europe, the Middle East, Africa, Australia and Asia, but not in North America.
Credits for the plastic parts go to Crown's Markus Graf, Jim Kraimer and Mike Gallagher, and Design Central's Ryan Berger, Thornton Lathrop and Rainer Teufel.
Specialized equipment manufacturer Morita Holdings Corp. won for a concept firetruck for use in battling large wildfires.
In developing a prototype over one year, designers expect to use vacuum forming, injection molding and glue compounds in various plastics applications for the polypropylene water tank, the PC side and rear panels and roof windows and ABS interior operational desk parts. Light-emitting diodes are the lighting source. The vehicle's center can function as an information base in the absence of a communication infrastructure.
Credits go to designer Takayuki Hamada and others on the team of Osaka, Japan-based Morita's technical laboratory.
Convergence strategist Native Design Ltd. of London and in-car location-navigation specialist TomTom International BV of Amsterdam won for the design of a portable satellite navigation system.
The TomTom GO-brand Live 1000 series standalone global-positioning-system unit has a housing of PC-ABS blend and a mounting of glass-reinforced PA. Neither part is painted. Contract processors in Taipei, Taiwan, and Shanghai injection mold the components.
The rear case is formed by pressed stainless steel. The glass touch panel measures 4.3 diagonal inches.
The mount and cable-attachment system uses magnets and flexible arrangements for usability and a secure connection.
TomTom introduced the system in the Netherlands in September 2010, initially at a price of 300 euros ($405).
Credits go to Native Design's Morten Warren, Marcus Hoggarth, Thomas Kleist, Jin Sang Hwang, Liam O'Brien, Tony Ferreira, Mads Koser and Pavel Pivonka; and TomTom's Ken McAlpine, Daniel Browning, Marco Bakker and Hayley Gaulton.
Design teams from aerospace giant Boeing Co. and industrial design firm Teague won two gold IDEAs for exterior/interior design and design strategy on the 787 Dreamliner.
The aircraft has an expansive inner architecture, dynamic LEDs replicating day-to-night light patterns, electronically dimming windows sans shades and large pivoting stow bins.
Reinforced polymer matrix composites account for as much as 50 percent of the primary structure, including the fuselage and wings. The one-piece wound-filament fuselage supplants six aircraft structures and eliminates use of 1,500 aluminum sheets and 40,000-50,000 fasteners.
Materials include polyacrylonitrile-precursor-based carbon fiber and epoxy resin from units of Tokyo-based Toray Industries Inc.; carbon molding composites for compression molded window frames from an operation of Stamford, Conn.-based Hexcel Corp.; and fuselage surfacing film, barrel-tooling bismaleimide and a process for vacuum-assisted resin-transfer molding of the aft pressure bulkhead from a division of Woodland Park, N.J.-based Cytec Industries Inc.
The twin-aisle aircraft seats 210-250 passengers and has a range of 7,650-8,200 nautical miles. Chicago-based Boeing's commercial airplanes segment is on a path to deliver its first 787-8 to All Nippon Airways Co. Ltd. for commercial flights projected to begin Oct. 26.
Walter Dorwin Teague Associates Inc. is the legal name for Seattle-based Teague.
A Continuum LLC design team in Boston and Mindray Medical International Ltd. of Shenzhen, China, won for a patient-monitoring system.
Materials include PC for the housings, polyester and silicone for overlays and cast aluminum for the dock base.
The scalable Mindray V series patient-monitor platform focuses on the clarity and continuity of data at a single point of care. Mindray introduced the system with V21 and V12 models in December.
In May 2008, Mindray paid $215 million for the assets of Datascope Corp. including its patient-monitoring business and its 129,600-square-foot facility in Mahwah, N.J., now operating as Mindray North America.
Design firm Zago LLC of New York won for an exhibit using water jugs at the Ecology Center in San Juan Capistrano, Calif.
The “Splash! How Good Water Works” display included Juggernaut or Juggie, a sculpture with 360 5-gallon bottles of PC or PET. Several other jugs were used in other parts of the exhibit.
Bottled-water-delivery company Paradise Springs Drinking Water Inc. of Santa Ana, Calif., donated the plastic jugs, each of which had reached the end of its life cycle and was destined for recycling.
Interactive environment-focused “Splash” says each Californian purportedly consumes 1,800 gallons of water daily, directly or indirectly, through a person's water footprint. A scenography with 10 problems and solutions helps a visitor experience the actual and virtual presence of water in products and services.
A portion of the exhibit notes the value to an individual of reusable water containers perhaps of stainless steel rather than disposable plastic bottles.
Nike Inc. subsidiary Hurley of Costa Mesa, Calif., provided funding though an initiative to inspire water literacy and access.
The exhibit opened in August 2010, has attracted about 3,500 visitors and closes Sept. 30.
Credits go to Nereo Zago, Muriel Dégerine, Nicole Pivirotto, Mayuko Soga, Manuel Toscano, Jenna Robles, Kevin Estrada, Julia Bessler, Richard Corr and Ryan Riegner, all with New York-based Zago, and the Ecology Center's Andrew Sieger, Gerard Basil Stripling and Evan Marks.
Environmental studio Evidence Design of Brooklyn, N.Y., won for its interactive “Science Storms” exhibit at the Museum of Science and Industry in Chicago.
Opened in March 2010, the permanent 26,000-square-foot display makes extensive use of Corian Illumination series solid-surface material from Wilmington, Del.-based DuPont Co. for structural and graphics panels.
Large-scale experiments explore the science behind tornadoes, lightning, fire, tsunamis, sunlight, avalanches and atoms.
For the avalanche, tons of glass beads and garnet sand are used, which flow over a rotating 20-foot-diameter disk with a surface coating of custom-formulated polyurethane. The disk is about two-thirds full of hundreds of half-inch photo-elastic disks of birefringent polymers. Polarized light is refracted in response to stresses visitors place on the disks. Production Resource Group LLC of Armonk, N.Y., fabricated the avalanche display, and Smooth-On Inc. of Easton, Pa., developed the coating, which has a high durometer hardness rating and a low coefficient of drag.
For the tornado, gallons of illuminated swirling water vapor rise in a 40-foot-tall air vortex. An ultrasonic fog system generates the vapor. The U.S. operation of 3form Inc. in Salt Lake City fabricated multiple tinted translucent resin panels. A glass-and-steel framework supports the tornado exhibit's curved walls. 3form flat panels with different tinting line two fabricated spaces used as classrooms.
For lightning, a large ceiling-mounted Tesla coil LSE transformer creates an indoor storm, discharging large, loud high-voltage electrical arcs.
Vistors can use reclined benches with internal lighting that are fabricated from custom thermoformed translucent acrylic. The acrylic was formed over wood forms and then trimmed to final specification on a five-axis router table. Lexington Design + Fabrication of Los Angeles built the benches.
The tsunami project uses mineral oil in a 30-foot-diameter seamless acrylic wave tank and three suspended 10-foot-diameter acrylic ripple tanks.
Credits go to Jack Pascarosa, Shari Berman, Len Soccolich, Rondi Davies, Carlos Fierro, Ari Nakamura, Laura Sheedy and Josh Whitehead, all of Evidence Design.
Industrial design-branding studio fuseproject won two gold IDEAs for the Jambox-brand system from mobile-lifestyle-specialist Jawbone of San Francisco, and the Clever Little Bag from footwear-apparel supplier Puma SE of Herzogenaurach, Germany.
The Jambox Bluetooth wireless audio speaker and duplex speakerphone has silicone-rubber top and bottom caps, rubber and glass-reinforced plastic internal components and a perforated stainless-steel grill with electrophoretic coating.
The Puma bag has elements of polyester and polypropylene but focuses on folding a cardboard sheet into a sustainable shoebox. That design reduces use of paper, water, energy and diesel. Puma and fuseproject developed the system over a 21-month period.
Yves Béhar and Gabe Lamb receive credit for the Jambox, and Béhar, Josh Morenstein, Nick Cronan and Seth Murray for the Puma bag. All are with San Francisco-based fuseproject.
The design team at One & Co. of San Francisco won for the Droid Incredible smartphone, which HTC Corp. of Taoyuan, Taiwan, manufactures using the Android operating system.
The unit has plastic, aluminum and stainless-steel components with a 4-diagonal-inch super-liquid-crystal display with a wide video-graphics array for the capacitive touch screen. The sculpted-metal back surface wraps over the interior components and provides a tactile experience in the hand.
Retail operations of joint venture Verizon Wireless of Basking Ridge, N.J., introduced the HTC Droid Incredible in April 2010.
Strategy consultancy Ziba Design of Portland, Ore., and the TDK Life on Record brand won for a 2011 line of audio products.
Incorporating numerous plastic components, the line includes a Sound Cube, two-speaker and three-speaker boombox systems and universal-serial-bus belt-drive turntable.
Several companies throughout Asia manufacture the products.
Imation Corp. of Oakdale, Minn., develops and markets TDK Life on Record-brand products under an exclusive long-term license acquired in 2007 from TDK Corp. of Tokyo.
Credits go to Ziba Design and TDK Life on Record.
Separately, Ziba with athletic equipment firm Li Ning Co. Ltd. of Beijing won a gold IDEA for research about China's emerging youth market.
Four student designs won gold IDEAs:
•Seth Astle of the Art Center College of Design in Pasadena, Calif., was recognized for his prototype Cadence prosthetic and pedal for cyclists with a below-the-knee amputation. He built prototypes of wood and an appearance model of ABS and plaster.
For further development, the main structure might consist of carbon-fiber-reinforced and hollow-glass-microsphere composites with MGS L285 epoxy resin and MGS 285 laminating hardener. Polypropylene is seen as a possible material for the socket and elastomeric rubber for the resistance band. Carbon fiber would be wound on blue closed-cell Styrofoam-type core.
•Nine students in the school of design at Dalian Nationalities University in Dalian, China, won a gold IDEA for a tent-rainwater collector. Credits go to Haimo Bao, Zelong Wang, Yunfei Zhao, Huan Liu, Kui Zhang, Feng Zeng, Yu Fu, Song Qiao and Kun Xu.
Intended for countries in Africa, the modular device collects rainwater, funnels it through filtering equipment under the roof and pipes it inside for cooking, drinking and washing.
Materials include the elastic waterproof housetop, filtering and importing equipment, rollable curtain, stretchy waterproof skin, pipes, fastener, activated carbon with high adsorption and KDF-type filter material.
•Veronika Scott of the College for Creative Studies in Detroit was recognized for the Empowerment Plan. The project would employ and educate homeless women in making the self-heated waterproof Element S Coat using Tyvek-type material, high density PE sheet, wool or quilted nylon, PVC tubing, nylon cord and Velcro fastener. A user can transform the coat into a sleeping bag at night.
•Craig Stover and Karl Sluis of the College of Creative Studies won for the Common Sense art exhibit, which, among other things, uses resin-bonded oriented strand board, foam board, medium-density fiberboard and plastic champagne glasses.
IDSA will announce winners of the best in show, curator's choice, people's choice and responsibility awards and recognize IDEA recipients at a Sept. 17 ceremony during the organization's conference in New Orleans. People's choice voting continues online at surveymonkey.com/s/ MNXMNK2.
Sponsors for the 2011 IDEA competition are joint venture Dow Corning Corp. of Midland, Mich., design and market research firm Lextant Corp. of Columbus, Ohio, and computer software firm Microsoft Corp. of Redmond, Wash. Fast Co., Yanko, Core 77 and Curve are media sponsors. The Henry Ford national historic landmark in Dearborn, Mich., will house the IDEA winners in its permanent collection.