Elite Plastics of Beaverton, Ore., a division of GM Nameplate of Seattle, molds the logo lens in a multi-cavity family tool. Tool design was simplified by molding each logo letter in a flat configuration as compared with their later installation along a curved surface. That development requires careful consideration of mismatched die pulls and requisite part draft. This approach minimized tooling cost while best matching the dimensional tolerance of the logo with that of the associated fascia panels.
3M Industrial Adhesives and Tapes undertook extensive testing of pressure-sensitive adhesives to determine the best formulation for permanently adhering the molded logo lenses to the painted surface of the pressure formed panels, ultimately achieving a bond stronger than the plastic itself.
Atlanta-based Quickparts services, an operation of 3D Systems Corp. of Rock Hill, S.C., provided rapid tooling and also molds numerous sub-components including the electric-vehicle plug components, dock and cable shroud using Sabic's Lexan EXL9330 PC and other enclosures and lenses using three of Sabic's Lexan PC grades.
The cable grommet is compression molded from 55 shore A silicone rubber from Shenzhen Genvan Silicone Materials Co. Ltd.
Smith Optics: Forefront bicycle helmet
Four designers won for the Smith Optics Inc. low-profile full-coverage Forefront-model bicycle helmet for mountain bike riding or racing.
A propriety adhesive is used to bond open-cell-construction panels from Koroyd SARL to Smith's expanded polystyrene helmet structure.
Koroyd co-extruded PC and a proprietary material creating a tube that Koroyd thermally welds into an engineered honeycomb core structure. Each tube has a diameter of 3.5 millimeters and a density to optimize energy absorption upon impact.
Incorporating Smith's Aerocore-brand construction and assembly method, the Koroyd design allows cool air via multiple channels to enter the helmet and hot air to escape. Smith Optics placed more vents throughout the helmet without sacrificing protection and comfort.
A VaporFit system relies on the integration of rotary-dial adjustments with a tuned elastic fit allowing a movement range of 5 centimeters and the ability to position the system at multiple attachment points for a rider's comfort.
The helmet's ventilated protection can integrate with sunglasses or goggles or with an optional mounting kit for a light such as one from Light & Motion Industries or a video camera such as one from GoPro Inc.
The goggle strap retention system is made of Hytrel thermoplastic elastomer from DuPont Co.
Nylon webbing is used in the chip strap and nylon 6/6 in the standard buckets and snap baskets.
Credits go to Drew Chilson and Mike Aaskov of Smith Optics of Ketchum, Idaho, and Piers Storey and James Rogers of Koroyd of Monte Carlo, Monaco.
The Forefront model was released in September at a price of $220.
Nokia Oyj: Nokia Lumia 2520 tablet
Creative staff in the Calabasas, Calif., design center of Nokia Oyj won for development of a computer tablet. The product was designed to compete with the iPad lineup from Apple Inc. and Surface devices from Microsoft Corp.
The Nokia Lumia 2520 tablet features a hard-coated PC unibody and a 10-diagonal-inch ClearBlack glass liquid-crystal-display screen with in-plane switching technology. The toughened display is coated in Corning Inc.'s alkali-aluminosilicate sheet known as Gorilla glass.
Other materials include polyurethane, stainless steel and cast magnesium.
Designers avoided use of materials with PVC and brominated flame retardants and excluded nickel from the product's surface.
The battery can charge to 80 percent of capacity in an hour.
The minimized packaging of renewable materials is 100 percent recyclable.
An optional Nokia Power Cover can transform the tablet into a mobile personal computer.
The Nokia 2520 in black, blue, red or yellow housings entered the market in October at prices starting from $399.
LG Electronics: Air Washer
Five designers from LG Electronics Inc. won for an Air Washer humidifier.
The humidifier has a housing of ABS for protection from external shocks, a top display of translucent acrylic and antibacterial discs of high impact PS for absorbing moisture. LG Chem Ltd. supplies the polymer materials.
The humidifier uses vaporization to evenly generate fine moisture particles. The humidification disc can kill 99.9 percent of all bacteria.
Adjustable lights on the top enable control of the unit at night.
Credits go to Saehwan Bae, Chinsoo Hyon, Jinsu Kim, Miju Kim, Jaeyong Park and Yunseo Jang at LG Electronics' corporate design center in Seoul, South Korea.
The Air Washer entered the market in late September at a price of $400.
Industrial designers with the Mike & Maaike Inc. studio won for creation of Haworth Inc.'s fully upholstered Windowseat lounge chair.
Furniture manufacturer Haworth works with Grand Rapids Foam Technologies of Wyoming, Mich., in creating the Windowseat's shape. The custom polyurethane foam fabricator uses a diphenylmethane diisocyanate process in overmolding foam padding onto the Windowseat's rigid steel frame.
The chair is suitable for a public or private space and incorporates elements exploring the idea of a sub-architectural space by creating a room-within-a-room.
The powder-coated steel base swivels with a return-to-center feature.
Windowseat meets standards of the Business and Institutional Furniture Manufacturers Association and the American National Standards Institute and carries the performance qualities of the Divina Mélange by Kvadrat surface collection.
Design credits go to Mike Simonian and Maaike Evers of Mike & Maaike in San Francisco.
Haworth introduced the Windowseat at the NeoCon design exposition in June 2013. The chair with canopy lists for $4,950.
FiftyThree: graphics pencil and packaging
Design and engineering firm FiftyThree Inc. won a gold IDEA for the packaging and graphics of its Pencil stylus and a silver IDEA for the product itself in the computer equipment category. The product takes the form of a traditional carpenter's pencil.
The highly advanced stylus is designed to work in harmony with the Paper application, another FiftyThree creation.
Some internal parts of the Pencil are injection molded of fire-retardant ABS from Chi Mei Corp. of Tainan City, Taiwan.
The rubber tip and eraser are molded of conductive silicone elastomer.
A tapered tip allows for a range of writing, drawing and shading angles with the Pencil's point being useful for fine details and the edge available for broad strokes.
The materials in the packaging include Mylar-brand polyester film from DuPont Co. along with raw pulp, raw cardboard and coated and non-coated papers.
Credits go to multiple FiftyThree designers. A team in Seattle designed the hardware, and a group in New York handled the software interaction aspects.
The Pencil entered the commercial market in November and is priced $74.95 for the milled sustainable-hardwood walnut version and $59.95 for the milled graphite-brushed aluminum model.
FiftyThree and two other firms won a gold IDEA in digital design for the Book. A system can transform a sketch made in an iPad Paper application into customized books from Moleskine SpA of Milan, Italy, or Milk Tailor Made Books Ltd. of Parnell, New Zealand.