DPSB: Design Process Support Bag

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Introduction: DPSB: Design Process Support Bag

This bag is used as a support during the design proces. It is made to easily store drawings, papers, material samples and much more. The bag is modular with different folders, Each folder can be use as the user desires. The folders are protect with a flat grey felt cover and come with straps to carry the bag around.

This bag is the result a semester time of designing, testing and prototyping. For the Project YourDesign, we are group 7.

Step 1: Tools

● ruler

● pencil

● cutter knife

● cutting sheet

● T-square

● needle

● hole cutter

These are all the needed to make this bag.

Step 2: Machinery

● laser cutter

● sewing machine

● jet-printer

You will aslo need to have the following machines availble.

Step 3: Materials

● 8 panels of Plywood, 350 x450 x 4 mm + 450 x 30 x 4 mm

● 1 sheet of felt 1500 x 500 x 3 mm or 1000 x 1100 x 3 mm

● 11 pairs off aluminium door hinges

● 44 bolts and nuts M4 x 12mm

● 28 washers M4, 1mm thick

● 1 complete Velcro strip (soft and hard side) 38mm x 290mm

● 1 complete Velcro strip (soft and hard side) 20mm x 120mm

● 2 elastic bands 380 x 30 mm

● 2 A4’s sticker paper

● 2 A4 ordinary paper

● 5 Self adhesive pockets

● 10 pieces of U-shape folders

● 1 belt 4000mm + buckle

These are al the materials that are used for this bag.

Step 4: Lasercut

Lasercut the 8 panels of plywood following the lasercut files. (appendix)

● 3 panels with holes

● 1 panel with cutouts for sketches

● 4 basic panels

Step 5: Cut the Felt

Take the felt sheet and lay it flat, make sure to use a cutting sheet to protect the table. Use a ruler, pencil/marker and cutting knife to carefully make the felt pieces. Measurements below show the correct outer dimensions.

Step 6: Make Holes

Now use a Panel as mould for the holes on the felt. Align The outer edges of both pieces with each other and mark the holes.

Use a hole cutter to make the openings.

Step 7: Fold Line Felt (optional)

Take a cutter knife and cut very lightly across the bending edges of the felt. This way, the felt is ‘forced’ to bend across these lines. This makes the handling of the tool easier. Careful not to cut through the felt!

The distance and side of where these cutlines are made on the felt piece 180 by 440 mm are shown below. The pieces 60 by 440 it’s only the middle line, hence no picture.

Step 8: Cut Lines Felt

The cutouts for the bag are shown in a technical drawing. You can find this in the appendix. Carefully study the technical drawing. You need a knife cutter, ruler and hole cutter.

Cut the lines according to the technical drawing.

Step 9: Sewing Velcro

The next step here is to sew the velcro on the felt. First start cutting the desired lengths of velcro shown on the technical drawing. You need a sewing machine to do this properly. Because of the thick felt, your thread can break while sewing, so take it easy. Note, there is a hard and soft side on the velcro. The soft side is the longest and the hard side is the short one. The sheet of felt should be symmetrical so it doesn’t matter which side you begin with, but the types of velcro should be on the opposite side of the sheet.

Step 10: Attach Straps

Now the belt can be attached to the bag. This is simply done by sliding it through the cutouts made in the felt.

Step 11: Handle

For the handle there is no technical drawing but a picture is shown below.

The blue and red are the velcro strips that needs to be sewed on the piece of felt. The blue and red color represent a velcro pair. This means a red velcro strip should stick to the other red velcrostrip. The belt is pictured by the gray object.

The result can be seen in the pictures.

Step 12: Elastic Bands

Also 2 elastic bands needs to be sewed together like shown in the picture. Make it overlap 2 cm and sew it together.

Step 13: Assembly Hinges

Now we will assemble the panels, door hinges and the felt hinges. The bolts and nuts are used everywhere. The washers are only used when there is felt involved, so the bolt won’t pierce the felt. Each hinge takes 2 bolts and 2 nuts and occasionally 2 washers.

Every pair of hinges has 2 parts: one with a hole and one with a pin. The orientation is important to use the modularity to the fullest. On each side of a panel there need to be 2 types of hinges. One pin and one hole hinge, as shown on the picture to the right. On the other side they need to be reversed mirrored. This means on the other side of a hole hinge, there is a pin hinge (and reverse).

Step 14: Assembly Small & Big Folder

Tomake a small folder you need:

● 1 panel (Users choice which type)

● 2 pairs of door hinges

● 4 bolts

● 4 nuts

assembly order: bolt - hinge - panel - hinge - nut

To make a medium or large folder you need:

● 2 panels (users choice which type)

● 2 pairs of door hinges

● 4 bolts

● 4 nuts

● 4 washers

● 1 piece of felt 60 x 440 ( medium folder)

or

● 1 piece of felt 180 x 440 (large folder)

assembly order: bolt - washer - felt- panel - hinge - nut

Step 15: Assembly Hinge & Cover

To connect the assembly of panels to the bag, there is a reinforcement rib provided.

assembly order: bolt - washer - bag - rib - hinge - nut

Step 16: Result

At the end you should have 1 large folder, 2 medium folders and 2 single folders.

These folders can be lifted into each other and form a bigger “book”. If the hinges aren’t connecting, there is a problem with the oriëntation.

Step 17: Step 7.5 Assembly Elastic Bands

The elastic bands can now be stretched over the panel with the cut outs.

Step 18: Step 8.1 Stickers Add-on

To make the design templates on the panels, you need:

● 1 A4 sticker paper

● Printer

● Pair of scissors or cutter knife

Start by putting the sticker paper in the printer. Print out the templates (appendix) and cut them out. Discard the adhesive protection and stick it to the desired plate.

Step 19: Step 8.2 Phase Cards Add-on

To make the design phase cards for labeling of the panels you need:

● printer

● normal A4 paper

● pair of scissors or cutter knife

● self-adhesive plastic pockets

Print out the labels on an A4 and cut them out. Take the self-adhesive plastic pocket and discard its adhesive protection. Stick it on the front side of every folder as there are five of them. You can choose where you put them on the board.

Step 20: Stap 8.3 A4 Pockets Add-on

Finally attach the 10 plastic U-shape A4 pockets to a basic Panel. Use double sided tape to attach these to the board.

Step 21: Step 9 End Result

The folders can be attached to eachother with the hinges, this can be attached to the cover. The cover goes around the folders and is closed with the velcro. The straps can be adjusted with the buckle.

This is the final result of the process.

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