Deakin University

School of Engineering
Faculty of Science, Engineering and Built Environment

Bachelor of Mechanical Engineering Honours S462

Product Development SED304

Exercise Equipment Challenge

Assignment: 2C –
Complete Report

Jack Gregory
216142787

Team 16
Timothy Gregory, Rohan Hamer,
Aaron Jones

Waurn Ponds, March 2018

Jack Gregory: SED304 Product Development, 2018, Trimester 1

Executive summary
The project was to develop a product for elderly users to exercise in an outdoor setting. The group
designed the product to be easily manufactured, safe, and as cheap as possible. The project did not
include creating a full-size prototype or the creation of any components. Group 8 used a ‘Four D’
product development process to design the product. We used empathy exercises and interviews
with extreme users to gain an understanding of the type of product that these users would enjoy.
See more about the ‘Four D’ process in the methodology section.

The product that group 8 designed was a “Balance Walkway”, that users can walk across. The
walkway is made from a soft rubber and foam material that will challenge the user’s strength,
stability and proprioception as they traverse the walkway. Unlike many common pieces of balance
equipment, the balance walkway provides a safe space for users to walk along-not just stand still.
The Balance walkway also has multiple hand rails that are a fun attraction for younger users such as
grandchildren of elderly people. The side hand rails include the option of a chain lattice and a rock
climbing inspired wall for children to climb across.

Acknowledgments
The authors would like to thank the following people:

Dr Kaja Antlej, for her technical and product development knowledge, Dr Clara Usma and Robert
Leen for their additional help in the development of this product and their engineering expertise,
Josh Humphries for his excellent advice about functional movements relating to elderly users and his
ideas for types for exercise equipment, the interviewees, for their generousness with their time and
honesty in their discussion, the people who we observed, for their kindness and trust, and lastly, to
the valuable members of team 16; Timothy Gregory, Rohan Hamer and Aaron Jones, who were
excellent members to work with.

Contents
Executive summary ................................................................................................................................. 2
Acknowledgments................................................................................................................................... 2
1. Project management....................................................................................................................... 4
1.1 Methodology........................................................................................................................... 4
1.2 Project management summary .............................................................................................. 5
1.3 Timelines and Milestones ....................................................................................................... 6
2. Introduction - Problem Identification ............................................................................................. 6
3. Background Research...................................................................................................................... 8
3.1 User Research ............................................................................................................................. 8
3.1.1 Extreme Users .................................................................................................................... 8
3.1.2 Observation ....................................................................................................................... 10
3.1.3 Interviewing ...................................................................................................................... 13
3.1.4 Empathy ............................................................................................................................ 14
3.1.5 User research synthesis and user profile .......................................................................... 16
Needs Criteria List ......................................................................................................................... 16

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3.1.6 User Persona ..................................................................................................................... 17

3.2 Market research ........................................................................................................................ 19
3.2.1 Local and global market analysis ...................................................................................... 19
3.2.2 Competitor benchmarking................................................................................................. 19
3.2.3Product price point .................................................................................................................... 21
3.2.4 Patent search ..................................................................................................................... 22
3.2.5 Legislations and Standards................................................................................................ 23
3.2.6 Market research synthesis ................................................................................................. 24
3.3 Technical research .................................................................................................................... 24
3.3.1 Current and Emerging Trends ........................................................................................... 24
Production processes and processability...................................................................................... 26
Current and Emerging Trends associated with user interaction and the aesthetics of the
product. ......................................................................................................................................... 27
3.3.2 Technical research synthesis ............................................................................................. 29
4 Concept design process ................................................................................................................ 30
4.1 Concept generation .............................................................................................................. 30
4.1.1 Inspiration board ............................................................................................................... 31
4.1.2 Hand Sketches and Story Boards ...................................................................................... 32
4.1.3 Mock Ups .......................................................................................................................... 34
4.2 Concept development............................................................................................................... 37
4.2.1 Development of individual concept proposal ................................................................... 37
4.2.2 Selection Matrix ................................................................................................................ 41
Scoring Matrix .................................................................................................................................. 42
5 Project proposal ............................................................................................................................ 43
5.1 Product Design Specifications ............................................................................................... 43
5.2 Aims, objectives and further work ........................................................................................ 44
6 Concept refinement ...................................................................................................................... 46
Refined trends ............................................................................................................................... 46
Design Development ..................................................................................................................... 46
Prototypes ..................................................................................................................................... 48
Revised PDS ................................................................................................................................... 51
Refined Concept ............................................................................................................................ 52
7 Engineering considerations ........................................................................................................... 54
7.1 Selected resources and processing modes (production) ...................................................... 54
Material Selection rationale: ........................................................................................................ 55
Process selection rationale: .......................................................................................................... 55

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7.2 Product life-cycle assessment ............................................................................................... 55

Life cycle assessment summary..................................................................................................... 58
7.3 Design for X principles .......................................................................................................... 58
7.4 Production cost estimates .................................................................................................... 60
Cost summary table ...................................................................................................................... 60
Cost analysis estimation................................................................................................................ 61
Break even analysis ....................................................................................................................... 61
8 Detailed design and engineering .................................................................................................. 61
8.1 Failure Modes and Effects Analysis....................................................................................... 61
Implementation of results to ........................................................................................................ 64
Design............................................................................................................................................ 64
8.2 Detailed design and engineering resolution ......................................................................... 65
Commercially Available Products Utilized .................................................................................... 70
8.3 Simulation analysis and design modifications: ..................................................................... 71
Simulation findings and implementation...................................................................................... 73
9 Final Design ................................................................................................................................... 74
9.1 Final prototype ...................................................................................................................... 74
.......................................................................................................................................................... 75
.......................................................................................................................................................... 77
9.2 Final communication and visualisation ................................................................................. 77
.......................................................................................................................................................... 81
9.3 Technical documentaition..................................................................................................... 82
10 Conclusions ............................................................................................................................... 82
10.1 Aims and objectives of the final design ................................................................................ 82
10.2 Evaluation of the final design................................................................................................ 82
10.3 Further work ......................................................................................................................... 83
References ............................................................................................................................................ 84
Appendices ............................................................................................................................................ 87

1. Project management

1.1 Methodology
The design process was based around a ‘four D’ process; Discover, Define, Develop, Deliver. In the
first stage, the designers research the market, the types potential users and the technical ways in

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which similar products achieve certain outcomes. Define is the stage where the developers define
the problem and generate some concepts. Develop, is the stage where the designers select or
combine concepts and develop existing concepts to create the best idea for the final product. Finally
Deliver is where the developers finalise the design and ensure that all areas such as manufacturing,
costing and life cycle analysis have been undertaken. They also create visuals for sales pitches to
potential investors.

1.2 Project management summary

Only four members of the group contributed to the product development process because Advine
Master unfortunately had an accident and was unable to complete the trimester.

The tasks were allocated based upon relative perceived strengths of each member in certain areas.
The tasks were allocated with a reasonable degree of fairness in mind, with each member being
allocated roughly the same workload. However, if a member was unable to put in the same amount
of time in a certain week due to external commitments, the group allocated them a smaller section
of the workload for that particular project.

There was a delay in the due date of assignment 2A for 48 hours, which impacted the next
assignment, assignment 2B. This affected the group’s ability to produce a quality prototype for
assignment 2B, as the 3D printer was still being used for assignment 2A submissions when the
prototype for 2B was needed. However, other than the delay in the work between 2A and 2B the
project ran almost identically to the Gantt chart depicted that was made at the beginning of the
trimester.

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1.3 Timelines and Milestones

2. Introduction - Problem Identification

Figure 1 Gantt Chart and task allocation showing the planned progress of the group work throughout the project, including tasks allocated to each
member and expected time to complete each task. See larger version of Gantt chart in appendix. See appendix 3

This design task is focused on the design and production of outdoor exercise equipment for seniors
that will improve their quality of life through increased ability to perform basic daily tasks.

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Figure 2 This is an age tree showing the ages and relative amounts of people in that age range based on two different
years; 1997 in light blue and 2017 in grey. It shows the percentage of people over 65 years has risen since 1997 and the
percentage of youths has decreased.

Anon, 2017. Feature Article - Population by Age and Sex, Australia, States and Territories. Australian
Bureau of Statistics.

According to (Anon, 2017. Feature Article - Population by Age and Sex, Australia, States and
Territories. Australian Bureau of Statistics) between the years 1997 and 2017 “the proportion of
people aged 65 years and over increased from 12.1% to 15.4% and the proportion of people aged 85
years and over increased from 1.2% of the total population in 1997 to 2.0% in 2017.”

“This group is projected to increase more rapidly over the next decade, as further cohorts of baby
boomers (those born between the years 1946 and 1964) turn 65.” (Anon, 2017. Feature Article -
Population by Age and Sex, Australia, States and Territories. Australian Bureau of Statistics)

This trend indicates a greater need for infrastructure and services to support the aging population of
Australia to ensure that this portion of the community can live healthily and happy lives.

“Individuals who were highly physically active showed 38% less risk of cognitive decline, and those
who did low-to-moderate level exercise also showed a significantly 35% reduced risk” (Bherer, L.,
Erickson, K.I. & Liu-Ambrose, T., 2013)

Therefore, it is important to engage these groups of people in an enjoyable way that can assist them
to live healthy lives. By ensuring the health of the elderly, the cost of their healthcare is greatly
reduced which not only is good for the individuals and their families, but also for the wider
community.

The project stakeholders are the professionals in the health industry such as general practitioners
and physiotherapists who work with elderly clientele, as well as the elderly demographic who wish
to maintain an active and healthy lifestyle. Other stakeholders are the state and federal
governments specifically through the allocation of funding to elderly care; the healthier the

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population is the less funding is required to provide a reasonable standard of life for this
demographic. Other main stake holders include the unit staff mainly Dr Kaja Antlej.

Local Councils are stakeholders if they consider purchasing exercise equipment.

3. Background Research

3.1 User Research

3.1.1 Extreme Users

Table 1 Extreme users table showing examples of Rejecters, Majority and Power users

Rejecters Majority Power

Inactive people (of all ages) Social and Athletes
recreational
exercising
small children people playing Fitness enthusiasts (all ages)
People with physical or People training for People training for physical
intellectual disability weight loss performance
including Deaf, Blind,
arthritis, Amputees, or
limited mobility
people with chronic injury Retirees People with elite level strength
and endurance
Very Elderly Physiotherapists
Obese Gymnasts
People requiring wheelchairs
People requiring Oxygen
tanks

Some extreme users of outdoor exercise equipment or similar public resources such as playgrounds
are listed above.

Athletes are a great example of power users of exercise equipment. For example; Johnny Reilly; a
dancer and mixed martial arts fighter uses park play grounds to complete workouts in preparation
for fights.

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Figure 3 An extreme user using equipment

Anon, 2013. Johnny BANG Reilly press ups

This is an extreme use for the equipment which in this case is a bench for walking across or balancing
on. Using park equipment in this way is very common with semi-professional athletes or other high-
performance athletes, especially those who travel often. When the athletes travel it is useful for
them to be able to use common areas like playgrounds to do their workouts rather than rely on
gymnasiums where there may or may not be the necessary equipment.

Figure 4

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Anon, Use of a wheelchair accessible swing

Persons with serious disabilities such as requiring an oxygen tank or a wheelchair are generally
rejecters of outdoor exercise equipment. Areas designed to include these people can contain;
wheelchair accessible swings and other equipment such as arm crank bikes – a stationary bicycle
that you power with your arms. These rejecters can offer insight to the physical needs of most users,
such as the amount of space around each item that should be included.

It is not uncommon for gym users or fitness enthusiasts to use park equipment to decompress the
spine. They do this by hanging form a bar either upside down or the right way up, which lengthens
the spine to counteract the compression due to gravity in everyday life.

Figure 5 A power user stretching the

spine after a workout

3.1.2 Observation

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Figure 6 The grandfather holding the child’s hands. The most relevant
needs of these two participants is to have an area or piece of
equipment that they can interact with together. The child is too young
and shy to play without his grandfather.

Figure 7 The grandfather supporting the child and preventing him from falling backwards with his body.

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Figure 8 The grandfather using his foot to steady the “Surfboard”. Therefore, the users need a steady ground, in this case
the sand, to stand on.

Figure 9 A power user stretching their

spine. This user needs a high bar to hang Figure 10 Note the way this user grips the bar due to an
from. injury on the middle finger. This person may need
larger padded grips on bars.

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Figure 11 A majority user using the equipment.

This person may not be comfortable with their
abilities or body and may need an area where
acceptance of individual abilities is cultivated.
Respect should always be shown in the area to
ensure this person feels comfortable.

3.1.3 Interviewing
See full interview transcripts in Appendix.

Interview findings and discussion

Biggest limiting factors for rejecters or reluctant users of exercise equipment:

One main challenge of exercising at an outdoor exercise facility is the motivation to workout may be
more difficult because you are more likely to be alone than in a gymnasium or at an organised event
such as yoga or table tennis sessions. “if you’re at the park at your own it’s a completely different
setting so you’ve really got to drive yourself through it.” If the exercise equipment or signage or the
surrounding environment of the equipment could encourage users to bring a friend or family
member, it is more likely that they would become regular users of the equipment.

“It is the feeling of what do they think of me, the judgement that’s really a big one.”

A major limitation for the use of exercise equipment, is the worry about the perception of the user
based on their abilities. This is particularly relevant to the outdoor exercise equipment because in an
outdoor setting there is likely to be many more people walking or driving past the area for the user

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to feel uncomfortable about. An area that encourages acceptance of each person’s abilities or has
some privacy from passers-by may be helpful in this regard.

What could be improved about current exercise equipment and what would make the biggest
difference to you and other users?

“A sign upon entry to the station explaining the rules and more importantly addressing, keeping the
clothes on, respect other users and put the ego aside because it’s a public gym it’s not a private
gym.”

The area should include a sign as the person from interview one suggested that has a code of
conduct and rules to follow when using the equipment, to ensure the comfort and emotional safety
of all users of the equipment.

“They have really good flooring so its normally some sort of rubber flooring, it’s not tan bark like a
normal playground. The bars are really secure so they are not unstable when you are hanging off
them. And every station has a theme to it”

The exercise equipment should be safe to use with soft flooring, not bark, as this could become a
trip hazard for people requiring a walker or walking stick, such as the person from interview three.

“see what each station is designed for, rather than, where do I start, I don’t know what to do, let’s
not do anything.”

The equipment should clearly show how to use it and what it is for, to make the users feel more
confident and certain about what they are doing.

Are there any exercises you think could be particularly beneficial to people who are inactive?

“For me that is doing some sort of squat/lunge movement, doing some sort of hip hinge movement,
and then a horizontal push and pull and a vertical push and pull. Targeting those four pillars you will
build a really good foundation with some core work and that will address any glaring weaknesses in
people that are relatively inactive”

The equipment should be designed to accommodate useful exercises that are relevant to the health
of a large proportion of people in the target demographic.

3.1.4 Empathy
The empathy exercise that our group undertook was to have one Tim wear a very heavy backpack
and walk up and down three stories of stairs; six flights. This exercise was intended to replicate the
effects of advanced age on the perceived difficulty of commonplace tasks such as climbing a stair
case or walking to the shops.

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At the beginning
of the exercise
Tim quickly scaled
the first few
flights of stairs,
but as he
continued he
gradually slowed
and used the
handrail for a
little more
support.

In these two photographs you can see Tim, weighed down by the back pack, is significantly slower than myself as
we climb the stairs.
Figure 12

Figure 14
Figure 13

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In this picture Tim is

completing the climb
to the top of the
stairs and is using the
handrail and has
placed a hand on his
knee for extra
strength to finish the
walk to the top stair.

Figure 15

In this exercise we found that even a slight difference in fitness ability; demonstrated by the heavy
backpack, makes a big difference in the perception of exercise and the enjoyment of the movements
used. We found that reduced fitness or additional weight plays a large role in preventing the body
from moving at its best. Tim is a very fit person in his prime but the artificial handicap we placed on
him impacted his ability to move at his best and for certain would influence his decision to work out
or exercise in future if the extra weight were permanent.

This exercise highlights the importance of designing for the weakest or most tired user. The user
should be able to safely stop at any given point when using the equipment, and if the user misplaces
their feet or makes a mistake when using the equipment, the equipment should either be safe, or it
should not make a large impact of the outcome or safety of the task.

3.1.5 User research synthesis and user profile

Needs Criteria List

User Requirements
1. To feel confident and comfortable with their ability
-to have the environment conducive to judgement-free interactions between different
physical ability users. Possibly through anonymous levels in the equipment, so no-one knows
how difficult it is except the user.

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2. To engage socially with other users and to feel accepted in that group
-To have the equipment or environment encourage respectful behaviour and social
interactions between users
-To have the equipment encourage interactions between users and their family such as
grandkids, by intelligent sizing of equipment to encourage the grandchildren to use the
equipment as well
3. To be safe emotionally
4. To be safe physically
-To be stable or supported when using the equipment
-To have a soft ground or area to reduce impact of falls
-To be able to adjust the equipment to suit the users unique body, or to have the equipment
generic to all body shapes and sizes so no adjustment is necessary
-To be protected from the elements such as sun
-To have adequate access to water

Stakeholder Requirements

1. Durable, long life span

-Minimum warranty e.g. 12 years
2. Affordable for a local council, government facility or private care facility.
3. Meet relevant Australian standards for all stakeholders
- AS4685:2014 Australian Playground Standards
4. Socially and culturally acceptable for the target demographic
5. That it will provide return through good performance reviews and testing, high use and
activity

3.1.6 User Persona

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Gladys - 72 years old, Anglo-Saxon, Buddhist What does she hear?

2 Children, 5 Grandchildren. 2 days per week babysits • “The grandchildren play video games too much
and need to get outside more”
Played golf in her middle age but stopped after a shoulder injury • “Hears on the news that elderly people should be
doing 30 minutes of exercise a day”
Used to do aqua aerobics until it was too tiring for her • “A lot of the negative consequences of being
inactive”
What does she say/do? • “She hears that going on a cruise is a good way
to meet other couples”
• “I’m getting too slow” • “She heard that people with pets are more
• “I’m not sure about standing up for so long” active, so thinking of getting a dog”
• “I wish I had more energy”
• “I’m going to aqua aerobics class”
What does she see?
• “I want to play golf again”
• “I’m so tired after a day with the grandkids”
• She sees similar aged people out exercising
• She sees on the Television the health benefits
What does she think/feel? associated with exercise such as delayed mental
decline
• “I want to get outside in the sunshine more often” • She sees her friends at the aqua aerobics out
• “Not feeling as energetic anymore” being more active
• “Feels concerned about her husband’s health” • She sees the garden gradually become less
• “She thinks she could be doing more with her time” beautiful with each passing year, and considers
• “She feels positive about her future” employing someone to look after it, even though
she used to love tending to it
• She sees herself becoming more overweight in
Gain the mirror
• She sees her grandkids growing up and is amazed
• I want more energy to spend time with family
at how quickly they grow
• I want to keep up with the grand kids
• I want to be less tired in the evening
• I want simple tasks to be less draining
• I want to feel younger
• I want help to be healthier

Pain

• Sore in her joints, especially her shoulder and knees

• She worries about her husband’s health
• She is frustrated with her husband because he watches too much television
• She is frustrated because she doesn’t like driving and worries about her vision, but the shops and local pool is too far to walk
• She is annoyed that she can no longer use her fingers as well as when she was younger and struggles to do the weekly samurai
sudoku in the newspaper

Figure 16 User persona including what a user might; See, Hear, Feel, Say or Do as well as what pain they feel and what they would like to gain.

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3.2 Market research

3.2.1 Local and global market analysis

There are approximately 560 local councils in Australia Anon, ABOUT ALGA. AUSTRALIAN LOCAL
GOVERNMENT ASSOCIATION meaning there is potentially 560 buyers of fitness equipment for
seniors just from local governments, with the potential for councils to purchase multiple sets of
equipment. Local councils are likely to be a large proportion of the market as they are responsible
for local playgrounds and parks.

In 2014 on the 30th of June, there were 2,688 Aged care facilities in Australia Anon, 2015. Aged care
industry facts which means there are a large number of facilities that would require exercise
equipment, depending on the relative ages and abilities of the patrons of these facilities.

There are 253 playgrounds in the Geelong region with five of them hosting fitness equipment.
Anon, Parks and reserves If the product this group produces can be marketed as both a playground
for children and as a piece of fitness equipment for seniors, it would drastically increase the number
of public parks that is would be investigated for.

The product detailed later in the report is likely to be to expensive for many of the smaller parks and
care facilities which will limit its use in these areas. However, it is likely to be very beneficial for the
health of the users as it can facilitate two of the four main movements necessary for maintaining
strength. Therefore, it is well placed to be used in larger or more opulent areas, or facilities.

On June 30, 2014, there were 186,278 beds being used in care facilities across Australia Anon, 2015.
Aged care industry facts which indicates an approximate maximum number of potential users.
However, obviously the product will not be used by all aged care facilities due to competition and
the budgets of each facility.

A 10% market share specifically for aged care would reach approximately 18,000 users, with about
250 units sold across Australia, assuming all facilities were upgrading their outdoor areas, in the time
that the product was sold. Similarly, a 1% market share equates to 1,800 users and 25 units sold.

Globally there were 962 million people aged over 60 in 2017 and that figure is expected to double by
2050. Anon, Ageing. United Nations.

The number of potential users of exercise equipment tailored to seniors is expanding exponentially,
which means the total number of exercise units sold across all companies is likely to increase with
each year, especially as it is likely more equipment will be designed specifically for seniors as this
section of the population grows in proportion to the general population. As the demand for this type
of equipment increases it is likely that facilities will have larger budgets for this type of equipment
meaning a larger proportion of units sold will be more expensive such as the product detailed in
later sections of this report.

3.2.2 Competitor benchmarking

Note: See other relevant Competitor Benchmarking tables in Appendix.

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Relevant competitors include; a_Space, ParkFit, ForPark Australia, and Australian leisure
management. However, of these suppliers many have the same products. “a_space” is the only
company that provides a price range for the equipment on the website. As the price range is a very
important consideration for product benchmarking, only a-space products were benchmarked. The
other companies had similar products as a_space so these three products represent a good
spectrum of products available for purchase.

Table 2 Competitor Benchmarking table

Metric Importa Units Dexterity Builder, Elliptical Trainer, Step Up Station

nce a_space a_space 300mm & 450mm,
factor a-Space

Ambiguous difficulty level 4 (Y/N) Y Y Y

Number of features that can be 3 # 0 0 0

used by multiple people

Number of features that can be 4 # 1 1 1

used or appeal to young children

Number of signs or related 4 # 0 0 0

equipment to encourage a
friendly atmosphere

Maximum fall height 5 Metr 0 0.4 0.45

es

Life Span years 4 Years 10 7 15

Retail price 3 AUD$ 0.95-1.2 5-7 1-1.5

x
1000

Meets applicable standards 5 (Y/N) Y Y Y

Socially acceptable 3 (Y/N) Y Y Y

Number of users per month 2 # 30 45 45

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The Dexterity Builder, a_space uses a handle that can be moved on a spiral track
that is used to support shoulder mobility. This apparatus scored highly for areas
such as emotional safety and “to feel comfortable with the user’s ability” as there is
only one level of difficulty. It however, does not have many ways for users to
interact and therefore did not score highly on areas such as “To engage socially
with other users and to feel accepted in that group”.

Figure 17 Anon,
Dexterity Builder

The Elliptical Trainer, from a_space is an elliptical trainer meaning users can train for cardiovascular
health by simulating running without any impact on joints on the machine. This apparatus is much
more expensive at $5,000-$7,000 which may mean it is too expensive for smaller or less wealthy
partys, such as private health care providers to purchase.

Figure 18 Anon, Elliptical Trainer

Figure 19
Anon, Step Up
The Step Up Station 300mm & 450mm, from a-Space was the highest scoring of the Station
300mm &
three types of equipment, mainly due to its affordability and long life span, which
450mm
makes it a more reasonable purchase for more types of consumers than the Elliptical
Trainer. It is also more likely to be regularly used as many types of people wanting to
get fit are likely to use it, when compared to the Dexterity Builder.

3.2.3Product price point

The design of the apparatus that the group selects after the concept generation phase will influence
the product price point to a large degree. If the selected concept is very large or has many features
that allow for more than one person to interact, or is likely to attract many users, then the price may
be higher to reflect these factors.

However, if the concept is not particularly unusual in terms of size, then the price should be in the
lower range of the usual amount for similar products. About $1000-$2500 is standard, based on the
prices from the competitor benchmarking, so an ideal price point would be $1,000. Most prices that
are readily available online do not include the price of installing the main upright pole at the sight. If
the cost of the groups product could include the cost of any uprights needed this would add a level
of convenience and be more attractive to potential buyers.

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If the shoulder resistance machine detailed in later sections of this report is selected, then the price
is likely to be much higher. The machine is very large compared to other equipment researched and
has LED lights and audio capabilities that would significantly add to the cost. As this equipment is
completely new, is likely to be used regularly and offers significant interaction between users, the
cost can be higher. Therefore, the ideal price point for the shoulder resistance machine detailed
later in this report is $17,000-$25,000.

3.2.4 Patent search

Table 3 Patent Search Table and Strategies not to infringe

Patent Number Description Diagram Strategy not to infringe

US 2007/0265142 This patent relates to the Avoid using multiple pieces of

A1 use of a central tower equipment attached to a central
which multiple pieces of tower. All equipment requires
exercise equipment are its own tower or sharing towers
attached to, this patent without an identifiable central
includes the use of tower.
different sized or different
types of equipment
mounted on a central
tower

US5419747 This patent is a specific A new approach must be used if

device, it covers similar equipment is to be used.
apparatuses that provides The mechanical parts of this
motion for all 4 limbs design should be avoided.
through the movement of Copying the movement that this
sliding foot pads and hand apparatus facilitates would
holds, it also covers the require a different design for
use of a stability aid to the machine.
support a user of this
apparatus.

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US7147591 This patent is a specific Two poles attached to one

device, this device uses 2 upright column cannot be used.
poles fitted to a column In addition, more than one set
which are used for various of two poles attached to a
exercises, this patent also central pole cannot be used
covers small variants in without infringing.
the application or
assembly of this specific
apparatus

3.2.5 Legislations and Standards

Below are listed relevant standards for playground equipment in Australia. The list includes general
or main standards and periphery standards as well as standards specific to different types of
equipment such as slides and swings.

The standards for the general maintenance and instillation of playground equipment:

Standard Title
Playground equipment and surfacing Development, installation, inspection,
maintenance and operation Main Standard
AS 4685.0:2017

Another relevant standard for playground equipment which includes the test methods
for determining whether the equipment meets the standards:

Playground surfacing - Specifications, requirements and test method Peripheral Standard

AS 4422:2016

The standards specific to playground equipment and Surfacing for Swings, Slides and Rock climbing
equipment:

Standard Title Specific Standard

Playground equipment and surfacing Additional specific safety requirements and test AS 4685.2:2014
methods for swings (EN 1176-2:2008, MOD)

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Playground equipment and surfacing Additional specific safety requirements and test
AS 4685.3:2014
methods for slides (EN 1176-3:2008, MOD)
Playground equipment and surfacing Additional specific safety requirements and test
AS 4685.6:2014
methods for rocking equipment

There are no regulatory bodies for the compliance of playground equipment that is comprehensive
to all providers of the equipment.

On public land such as parks, the local council or a local parks body (if applicable; not all councils
have a designated park group) is responsible for the adherence to the Australian standards.

On private property such as in nursing homes or other care facilities, there are essentially no
regulatory bodies. However, if an accident occurs due to negligence, a fault in the equipment or
similar circumstances, individuals may take legal action. In this way the users of the equipment act in
a similar way to a regulatory body, only in a case by case basis, and only if an incident occurs.

3.2.6 Market research synthesis

The push/pull machine is well placed to go to market based on the number of potential buyers and
the comparative anticipated results of the competitor benchmarking. It is a relatively large purchase
but would likely perform well in the catagories such as number of features that would appeal to
children and number of features that facilitate user interaction from the competitor benchmarking.
It is also likely to attract a large number of users per month and it has an ambiguous difficulty level,
with the movement of the handles, this means it is less likely to be intimidating to new users.

If the product can capture a 1% market share of the exercise equipment at care facilities in Australia
then there would likely be approximately 25 units sold. However, local councils are likely to be a
greater contributor to the number of units purchased as the product appeals to children and adults
alike and could become an attraction of people to a park. The price of the apparatu will mean that
only the areas with a high number of potential users would consider this equipment; it is unlikely to
be pruchased in lower population areas or for smaller parks and playgrounds. This means that it is
likely to control a smaller market share than a cheaper product in the $1,000-$3,000 range.
However, it is likely to be much more attractive to younger users such as the grandchildren of elderly
people, so it is well placed to sell enough units for it to be financially viable.

3.3 Technical research

3.3.1 Current and Emerging Trends

Below are some examples of materials used for various types of park fitness equipment, with the
type of exercise that it targets and the type of equipment used, e.g. if the equipment has moving
parts-Dynamic or if it is stationary-static.

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Table 4 Examples of current materials used in park fitness equipment, The City of Sydney’s Park Fitness Equipment Plan
2015.

Name/ Equipment Exercise

Image Location Layout type type Materials Used
Bondi Park, Hub Static Aerobic Painted timber
Bondi Beach Anaerobic posts and
Stability benches with
Flexibility marine grade
stainless steel
rails and caps.

Burrows Park, Hub Static and Aerobic Powder-coated

Clovelly Dynamic Anaerobic marine grade
Stability stainless steel
Flexibility with plastic
benches and
seats.

Arthur Byrne Hub Static and Aerobic Powder-

Reserve, Dynamic Anaerobic coated,
Maroubra Stability zinc-plated
Beach Flexibility steel
with plastic
benches and
seats.

Camperdown Hub Static and Aerobic Powder-

Park, Dynamic Anaerobic coated,
Camperdown Stability zinc-plated
Flexibility steel
with plastic
benches and
seats.

Eric Primrose Hub Static and Aerobic Powder-coated

Reserve, Dynamic Anaerobic galvanised
Rydalmere Stability steel
Flexibility with
aluminium
benches.

Wentworth Trail Static Aerobic Galvanised

Park, Anaerobic steel
Glebe Stability posts and rails
Flexibility with stained
timber
benches.

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Figure 20 Yield strength and Density of common equipment materials, CES Edu Pack 2015

Production processes and processability.

Below are the material properties regarding the processability of the materials in the above table
and graph. These are the most common materials for park equipment. The higher the number; the
easier it is to process the material, here 1 correlates to a very difficult process and 5 relates to an
easy process to make, join, shape and finish the material.

Softwood pine

Figure 21

Hardwood

Figure 22

Non Age-Hardened Wrought Alloys

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Figure 23

Low carbon Steel

Figure 24

Polymers (ABS)

Figure 25

CES Edu Pack 2015

Current and Emerging Trends associated with user interaction and the aesthetics of the
product.

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Figure 26 Expression Swing (GAME TIME, 2018)

The swing allows adults and young children to use the swing at the same time. This type of
equipment that facilitates child and adult interaction is an emerging trend in the design of park
equipment.

Disability access is also an important trend as it allows for more people to access playground
equipment. Equipment such as this disability swing have become more common in the last few
years.

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Figure 27 Anon, Use of wheelchair accessible swing

Figure 28 Outdoor Fitness for Smart Cities, (URBANGYM, 2018)

An emerging trend that makes the equipment more appeaing is using technology to help users to
use good technique, stay motivated and try new movements. This type of technology is called
‘Personal Virtual trainers’.

3.3.2 Technical research synthesis

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The equipment that the group selects should ideally have features that align it with some of the
trends highlighted in the previous section, such as 'smart fitness' and accesibility.

The equipment should be highly user interactive and include technology such as a virtual personal
trainer and allow the user to easily add their workout to apps on their smart phone or watch. This is
less likely to be usefull for the elderly users but will still benifit other users or assist helpers of the
elderly or disabled to track the exercise of the user. The equipment could achieve this by having a
guide to the number of repititions at each difficulty to the energy burned or automatically track the
energy expended through the movement of the machines parts.

The equipment should allow for interaction between adults and children such as through the
'expression swing'. This can be accomplished by designing the equipment to allow adult and younger
users to interact at the same level; for the users of all ages to be easily able to look each other in the
eye. This could be accomplished through the use of different layers on the ground that the users
walk on-higher for shorter users. The equipment needs be interesting for both adults and children, in
order to acheive the maximum use of the product. Light up diplays can easily be customised for each
individuals ability and is likely to add a level of interest for all generations.

Wide walkways and ubiquitous hand rails would allow people with a greater range of abilities to use
the equipment. It is also important to provide access to drinking water and shade to accomodate all
users.

The materials used should be easily processed and be cheap to make and to shape into the desired
form.

4 Concept design process

4.1 Concept generation

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4.1.1 Inspiration board

Figure 29 Inspiration Board. Note: See full size Inspiration Board in Appendix

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4.1.2 Hand Sketches and Story Boards

Figure 30 The apparatus is a push or pull machine with resistance

The apparatus will give elderly people the opportunity to complete a push and pull movement
against resistance in both horizontal and vertical orientations.

Figure 31 The outside of the equipment serves as a playground for children to play on with rock climbing grips for them to
climb up

Figure 32 The rods slide in and out of tubes, which provide obstacles for children to play around and to climb

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Figure 33 Showing a possible method to change the colour of the outside tubes and handles

The tubes and handles will include LED lights that can change colour. A control panel would allow
the user to pick the colours. The colours would change when the handles are pushed or pulled giving
an incentive to use the machine. The resistance could also be adjusted at this control panel.

Figure 34 The machine will have an option to play musical notes or music when the handles are pushed or pulled providing
more incentive to use the machine

The machine can be used to play a sporting anthem or a simple song with the handles. A fence at the
top of the machine would reduce the number of falls, keeping the children playing on top and the
adults and children below safe.

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Figure 35 The tubes light up enough to provide enough light to use the equipment at night and to make it look visually
appealing when it is dark

Figure 36 The roof will be opaque or semi-opaque to shelter the users from the sun, but the sides will allow light in for them
to see and for them to keep an eye on their kids, if they are playing on top or outside the apparatus.

4.1.3 Mock Ups

Figure 37

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Study of composition
Where do the rods go when pushed?

• They could go up into tubes on the top, supplying an extra thing for kids to climb on/play
around.
• The tube should be shorter than the length of the rod that has the handle so that it can’t get
stuck in there.

Figure 38 Demonstrating the rods sliding in and out of the tubes when a user pushes or pulls the handle

What geometry? Angle at start etc?

• The angle at the bottom of the rock wall part of the apparatus should not be vertical as this
would likely be too hard for younger children and would make any falls more likely to be
dangerous.
• A slide could encourage children to play on the top.
• A flat top would allow for more handles from the ceiling and a safer playing place for the
kids on top.
How can it be safe?

• May need to put a fence on the top so kids can’t fall off edges. If it were three sided instead
of two it would reduce the places to fall off.

Figure 39 Figure 40

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Study of Scale
How large are the rods?

• This is not important for the user interactions, but it is important for the strength of the
handles and the length of time the apparatus lasts.

Do they start up or down?

• As long as the handles to not go too high so that the adults can’t reach them or too low so
that the users would need to duck or walk around them, then the handles could remain at
whatever position they started with.
Would it be possible for the kids to climb up the inside?

• The height of the ceiling should be just greater than the average reach height of an adult so
that they can grab the handles when they are fully pushed in. It should be tall enough to
discourage children from swinging from the handles.
What’s the scale?

• The length should be great enough that when the handles are fully extended an adult can
comfortably walk between them. Ideally two adults to allow for larger people.

Figure 41 Pictures showing an approximate scale

Study of Ergonomics/functionality
What type of handle?

• A mixture of types of handles would give the most benefit. E.g. Tubes on each orientation,
door knob, rope etc.

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• The handles should not be too large or the average hand could not easily wrap around the
whole handle
Is there resistance on the push/pull things?

• Yes, resistance could be varied for each of the handles or it could possibly be adjusted by a
display. The display could also adjust the colours of the handles.
Interactions;

• Could change colour with LEDs so when you move the handles they might change colour. Or
they could make a sound.
• There would need to be extra handles like rock climbing handles at the start of the rock wall
to help the kids get up. These could change colours as well.
• There could be music that you play by pulling certain handles.
• You could change the colour of the handles to your footy team by pushing/pulling and
selecting the colour on a display.
• The handles could light up one by one so when you pull them it plays the notes of a song.
E.g. hot cross buns or the user’s favourite Football anthem.
• Could be clear roof would allow parents to keep an eye on kids on the roof from below.

Figure 42 Images showing the width of the handles affecting the grip strength

As shown in the above images, the width of the handles will have an affect on the ability of the user
to properly grip the handles. In the left image, the handle I too wide and the hande does not fully
wrap around the handle, weakening the grip strength.

4.2 Concept development

4.2.1 Development of individual concept proposal

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Figure 43 An inside view showing the handles on the inside that can be pulled or pushed to increase shoulder and torso
strength in users.

There are 37 total handles that users can push or pull with varying levels of resistance. There are two
orientations; vertical and horizontal so that the user can improve their strength in both planes with
only one apparatus. The further into the machine the handles are the greater the resistance.

Figure 44 An outside view showing the whole design, including the tubes that the handles retract into, which form obstacles
for children to climb on, and play around.

The shell of the apparatus forms a play area for children. It is hoped that seniors and their
grandchildren would use the equipment together.

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Figure 45 The tubes and handles light up due to LED lights on the inside of the semi-transparent tubing.

The lights in the design provide an incentive for the user to move the handles, and they provide an
option of controlling the colour based upon a display located at the back of the apparatus.

Figure 46 The handles can change colour based upon the movement of the handles, and do not all need to be the same
colour. This would allow colour options such as a football teams playing colours or a colour scheme of the user’s creation.

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Figure 47 The movement of the handles in and out of the light up tubing.

Bump switches located at the back and front of the tube change the colour when the handle is fully
extended and fully retracted. As the handle completes either a forward or backward movement, the
rod it is attached to hits the bump switch, changing the colour to the colour set on the display. If the
tube is already the designated colour, a new colour is chosen at random.

Figure 48 A scale model of the design featuring two average sized adults using the handles on the inside

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Figure 49 Two young children using the top of the apparatus as a play area. The roof of the design is a black polymer to
shield occupants from the sun.

Figure 50 Another scale representation of the design, showing two adults and two children using the apparatus. Also
highlighting that the walls are semi-transparent plastic to allow the adults to monitor their children’s play from inside the
apparatus.

4.2.2 Selection Matrix

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________________________________________________________________________________________________________________
Walking Balance ball Assisted Seesaw Resistance Cable Interactive shoulder
Scoring Matrix Machine strength machine

Jack Gregory
Rohan Hamer
Aaron Jones
Timothy Gregory
Selection criteria Weight Rating Weighted Rating Weighted Score Rating Weighted Rating Weighted
% Score Score Score
Ambiguous difficulty level 10 2 0.2 3 0.3 3 0.3 3 0.3

Socially engaging between strangers 9 2 0.18 1 0.09 1 0.09 5 0.45

Facilitates interaction between adults and their children 10 5 0.5 5 0.5 1 0.1 5 0.5

Facilitative of a friendly atmosphere 10 5 0.5 5 0.5 3 0.3 4 0.4

Physical safety 15 4 0.6 3 0.45 5 0.75 2 0.3

Durable, long life span 13 3 0.39 3 0.39 5 0.65 2 0.26

Affordability 12 5 0.6 3 0.36 5 0.6 1 0.12

Meets applicable standards 8 5 0.4 5 0.4 5 0.4 5 0.4

Socially acceptable 8 5 0.4 5 0.4 5 0.4 3 0.24

Large number of users 5 4 0.2 3 0.15 1 0.05 5 0.25

Total Score 3.97 3.54 3.64 3.22

Rank 1 3 2 4

Continue? Develop No No No

Table 5
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________________________________________________________________________________________________________________

The Selection matrix was used to determine the best concept based on the user needs. The matrix
was made based upon the user needs found in other concept generation phases. The needs were
assigned a weighting or importance value. The concepts were rated based on how well they satisfy
the user requirements, and this number (1-5, 5 is good) was multiplied by the weight to give each
concept a score for each user need. The concept with the highest total score was ranked as number
one. Concepts could not be combined as each design was significantly different. The concepts of the
Resistance Cable Machine and the interactive shoulder strength machine both allow the user to
strengthen their shoulders and arms, but the approach taken is very different and not compatible.
Similarly, the walking balance ball and assisted seesaw are very dissimilar.

The concept that scored the best and was chosen to be developed was the walking balance ball. This
apparatus did not score exceptionally highly compared to the other concepts in any category but
was scored well in each individual criterion.

5 Project proposal

5.1 Product Design Specifications

Design Category Specification
Lifetime Product must have a lifetime of 10 years of outdoor use.
Retail price Cost under $8000 AUD
Durability Product must be able to withstand consistent use and resist damage.
Anthropometric use Product must be safe for a large height and weight range, from 80-
200cm tall and from 5-120kg.
Manufacturing To be made locally from as many locally sourced materials as possible
Materials Material selection to minimize carbon footprint.
Loading Product to be able to be safe for up to 5 users.
Number of parts To be constructed with under 10 unique parts.
Rate of manufacture 1 unit to be manufactured under 1 week.
Temperature range Able to withstand the Australian climate (-10° C to 50° C).
Size To take up less than 20 square meters.
Foundations Foundations must not require excavation depth of more than .5
meters.
Standard Must meet all required standards. (AS 4685.0:2017)
Maintenance Maintenance free for a minimum of 24-month intervals.
Disposal To be made from mostly materials that can be recycled at end of life.
Table 6

The product design specifications for the Walking Balance Ball contain the major specifications that
the end design should meet.

The price should be lower than $8000 Australian dollars to appeal to potential buyers such as local
councils and the upper range of health care facilities in terms of budget.

The life span of 10 years or more is very important in regard to ensuring the product is worth
purchasing for these buyers. The equipment is a large investment, so a long lifespan is paramount to
ensuring the equipment is an attractive proposition to potential buyers.
Jack Gregory: SED304 Product Development, 2018, trimester 1

The equipment needs to be safe for up to 5 users at any time with weights of up to 120 kg. This
ensures even with misuse; the product will still be safe. The equipment is designed to accommodate
an adult and up to 2 children using the equipment at the same time, but should still be safe for a
greater number of users.

The equipment should take less than 20 square metres of space and require no more than 0.5
metres depth for its foundations to fit into smaller outdoor spaces, such as courtyards or in a
playground or similar setting.

5.2 Aims, objectives and further work

Figure 51

The design that was chosen was the Walking balance ball. This design utilises a long track that users
walk across whilst striving to maintain their balance. The track is made from flexible rubber that has
been inflated so that when the user puts weight on it, it compresses slightly, providing an unstable
platform for the user to walk across. The track provides a safe area for users to work on their
balance, as the hand rails provide support to reduce the likelihood of falls.

The track uses a similar concept to the widely used “BOSU Ball.” The surface is unstable enough to
challenge the stability and proprioception of the user.

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Figure 52 The BOSU ball can be used to train balance and increase proprioception. Anon, BOSU® PRO BALANCE TRAINER

The inflatable rubber track provides a fun place for young children to run or bounce across,
facilitating interaction between young and more senior generations; particularly seniors and any
grandchildren they have in the 4-10 years old range.

Unlike a BOSU ball, multiple users can use the apparatus simultaneously, which provides a friendlier
environment between users. Unlike most outdoor exercise equipment readily available in Australia,
the groups’ concept can help improve balance, through the use of an unstable flooring, compared to
most equipment that uses a solid floor plate that can rock back and forward, similarly to a seesaw,
or a thin beam to walk across.

The design needs to be refined, in particular the method of joining the rubber upper surface to the
base plate. The seal needs to be air tight and very strong, to prevent the leakage of air through the
seams. Similarly, the material of the rubber top needs to be selected to ensure that it is strong and
durable enough to withstand 10 years of outdoor use, without leaking. An inner material or bladder
may also be designed to add another layer of protection against leaks.

The hand rails should be refined to better suit the users need regarding sizing and shape. Potentially
a more rounded corner that extended past the ends of the walking track would allow the users to
grip the handrails prior to mounting the walking track.

The specific Australian standards for similar balance equipment should be researched. Other
standards such as the surrounding ground surface should also be researched.

An Interdisciplinary research methodology will be used to research the improvements to the team’s
concept in the next stage of the design process. All members regardless of the stream of engineering
and other collaborators, such as playground equipment experts and exercise equipment
manufacturers should all share knowledge and resources to best design the final concept and
manufacturing processes of the groups project. Other possible collaborators include material
scientists and business professionals or entrepreneurs with similar products.

The life cycles of all the materials must be researched in order to plan for end of life stages, such as
recycling. The manufacturing also needs to be considered, particularly how the process can be
streamlined, through the reduction in number of parts unique to the groups concept and other
methods.

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6 Concept refinement
Refined trends
Aramid fibre is gaining popularity in the plastics industry due to its high strength and good resistance
to abrasion. Anon, What is aramid? The aramid fibre will allow the pillow track to withstand greater
use and mean the pillow will be able to support more weight and last longer.

HDPE is a widely used plastic that is impact resistant and strong meaning it will withstand any
impacts due to climbing and playing near the walls of the equipment. It is also weather resistant and
long lasting, which means it will be a suitable choice for both indoor and outdoor facilities. Anon,
2017. High Density Polyethylene (HDPE): So Popular It is also readily recyclable.

Artificial rock climbing walls are a popular attraction for young people including children with 1,000
to 1,500 people trying rock climbing for the first time each day in the U.S. Anon, Key
Figures. International Federation of Sport Climbing. 39% of climbers are aged under 18, which is the
target demographic of the rock wall feature of the design. Anon, Key Figures. International
Federation of Sport Climbing.

Design Development
The original concept utilised two hand rails and the one walking track.

Figure 53 The first iteration with the basic hand rails and pillow track

The second iteration utilised walls instead of handrails that could have rock climbing grips for
children to play on.

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Figure 54 The second iteration showing a rock climbing wall functioning as the hand rail

The third iteration has modular components that aid manufacturing as all components can slot into
each other allowing for a large number of options for customers to choose from. The hand rails have
three options: Basic hand rail, hand rail with a chain lattice for children to climb along and a wall
with rock climbing grips on the outside. More hand rail designs are being considered but the above
three options are being produced currently in this unit.

There are two walking tracks: a ramped flat track, that allows the user to slowly become accustomed
to the softness of the walking track as they mount the equipment, and the plain flat track. More
tracks are being considered including differing softness and steps or ridges to further challenge
users.

Figure 55 Showing possible hand rail designs including basic, rock climbing wall and horizontal bars.

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Figure 56 Two types of pillow track and the foundation that all tracks attach to. The base features holes where the hand
rails will be attached.

The customer can choose to purchase a singular piece or multiple items that can form a walking
track with varying degrees of difficulty, all of which is highly customisable before purchase.

Figure 57 Concept sketch showing a possible walking track of multiple pieces of equipment each with a different challenge.

Prototypes
The first iteration of the prototype includes the rounded edge pillow track and basic handrails. It also
has the option of having a rock climbing wall on one of the walls for children to climb along whilst
still interacting with their eyes at roughly the same height as the adults’. The hand rails now extend
past the ends of the pillow track to allow users to grab the rails before mounting the track. Please
note: The individual rocks on the rock wall were too small to successfully 3D print, but will be
located on the outside of the wall in the full-sized product.

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Figure 58 The first iteration of the prototype featuring rock climbing wall and a rounded pillow track

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The second iteration of prototypes included modular hand rails and two types of pillow, including a
ramped, flat pillow that allows the user to gradually adjust to the softness of the track as they climb
up the ramp.

Figure 59 The ramps of the flat track allow the user to gradually adjust to the track.

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Figure 60 The design allows users to interact with each other at a similar eye level as one user climbs along the rock wall
and one walks along the track

Figure 61 The flat track has no sloped edges on the sides where the wall borders the track to prevent a trapping hazard for
feet.

Revised PDS

Design Category Specification

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Lifetime Product must have a lifetime of 10 years of outdoor use.

Retail price Cost under $8000 AUD

Durability Product must be able to withstand consistent use and resist damage.

Anthropometric use Product must be safe for a large height and weight range, from 80-
200cm tall and from 5-120kg.

Manufacturing To be made locally from as many locally sourced materials as possible

Materials Material selection to minimize carbon footprint.

Loading Product to be able to be safe for up to 5 users.

Number of parts To be constructed with under 10 unique parts.

Modularity All hand rail pieces and track pieces can be exchanged in all products.
The joints are generic to all components.
Foundation modularity All design modules require the same concrete base.
Customizability of Rock The rocks on the rock climbing wall can be custom placed for the
wall customer if desired
Rate of manufacture 1 unit to be manufactured in under 1 week.

Temperature range Able to withstand the Australian climate (-10° C to 50° C).

Size To take up less than 6 square meters.

Foundations Foundations must not require excavation depth of more than 0.5
meters.

Standard Must meet all required standards. (AS 4685.0:2017)

Safety The track must be flat, when viewed from the front, to avoid a
trapping hazard for feet between the track and the hand rail.

The hand rails extend further than the track, to allow users to grasp
the hand rails prior to mounting the walking track.
Maintenance Maintenance free for a minimum of 24-month intervals.

The pillow/track can be removed for maintenance

Disposal To be made from mostly (all except rubber and foam) materials that
can be recycled at end of life.
Hand rails and pillow track can be removed from base by a contractor
Sourcing Parts and manufacturing should be sourced locally where practical
Table 7

Refined Concept
The refined concept is modular. The purchaser can choose from two types of pillow track; the flat
track with ramps and the rounded edge track. Customers can also choose the type of hand rail with

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options including; basic- a hand rail, a rock climbing wall and a chain lattice.

Figure 62 The basic options for the Balance walkway including a rock wall, and chain lattice as well as two types of pillow
track.

The pillow track can be removed for maintenance or replaced if the client desires a different type of
pillow track after a period of use. Similarly, the rails can be updated if desired.

Figure 63 The rock wall is brightly coloured to be attractive to children

The rock wall and chain lattice are designed to be very attractive to young children who will make it
more likely for senior users to return and use the equipment on a regular basis.

Figure 64 Users can hold the hand rails as they walk across the balance pillow track. Note the users’ feet will sink into the
pillow which provides an unstable platform to challenge their balance.

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Figure 65 Children and their guardians such as their grandparents can interact whilst they use the equipment as they will be
at a similar eye level.

7 Engineering considerations

7.1 Selected resources and processing modes (production)

Component Foundation Standard Side Rock wall Side Chain-climb Rounded Pillow Wedged pillow
side
Image

Material 20Mpa Concrete Powder -Powder coated -Powder - Open Cell foam -Open Cell foam
coated 1018 1018 Mild Steel coated 1018 -Rubber-coated -Rubber-coated
Mild Steel -HDPE Sheet Mild steel aramid fibre aramid fibre
-Climbwall -5mm gal cover cover
fittings chain
Manufacturing Cast in ground at Standard Standard Tubing Standard Foam core to be Foam core to be
point of Tubing will will require 2 Tubing will cut into shape cut into shape
installation. require 2 Bends by require 2 Bends before being before being
Ensuring top Bends by hydraulic tube by hydraulic fitted into fitted into
surface is hydraulic tube bender with tube bender durable durable
sufficiently low bender tabs welded for with Chains cut aramid/moulded aramid/moulded
to have tyre fixing HDPE and welded in rubber cover rubber cover
crumb coating Sheet place.
Table 8

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Material Selection rationale:

The Foundation will be made from 20 Mpa Concrete as concrete provides a strong and stable base
for the pillow that will not degrade druing the expected life of the product.

The Standard side tubing is a low cost steel that is useful where the highest strength steel is not
required. In the deisgn, the steel is only required to support the mass of the wall and children
climbing and swinging on it. The tubing is also recycleabe and once powder coated, it is corrosion
resistant.

Rubber coated arimid fibre will provide a good resistance to wear and dilleberate mistreatment such
as cutting or stabbing. The rubber will allow the user to sink into the foam without impacting the
resistance to a great degree.

The open cell foam was chosen because it provides the desired softness whilst also providing
enough support for the user.

The 5 mm galvinised chain is large enough to support the weight of the users climbing on it.

HDPE is a common material used in playground equipment as it has a high strengh to density ratio,
meaning it is strong but also lightweight, allowing for easier instillation. Anon, 2017. High Density
Polyethylene (HDPE): So Popular It is shock resistant which is important for use where children may
fall against it and it is durable and will not break down over the life of the product. It is also readily
recyclable. Anon, 2017. High Density Polyethylene (HDPE): So Popular

Process selection rationale:

The foundation needs to be cast at the point of instillation in order to avoid transport of a very
heavy base.

The tubing will be bend by a hydraulic tube bender rather than welding three sections together as it
is cheaper and quicker to bend steel compared to weld multiple pieces.

The chains need to be welded in place by hand, as this is the only reasonable method (that is durable
enough to last the lifetime of the product) of attaaching them to each other to form the lattice.

The foam core will be cut into shape and fitted into the rubber coated arimid fibre cover. The cover
is fitted by hand as this provides a cheaper alternative than by automation, for the low expected
volumes for this product.

All of the above processes will be undertaken in Australia with most completed locally in Victoria.

7.2 Product life-cycle assessment

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Figure 66 Life Cycle diagram

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MET Matrix
INPUTS OUTPUTS
(M) Use of Materials (E) Use of Energy (T) Toxic Emissions CO2
Primary Material Production Concrete
and Material Processesing Primary Material Production 1-1.3 MJ/Kg 0.0903-0.0998 Kg/Kg
Material Processing 2.06-2.28MJ/Kg 0.155-0.171 Kg/Kg
Water Usage 3.23-3.57l/kg
Mild Carbon Steel (< 0.25%)
Primary Material Production 25-27.7 MJ/kg 1.72-1.9 Kg/Kg
Material Processing 4.86-5.37 MJ/kg 0.364-0.403 Kg/Kg
Water Usage 43.2-47.7 l/kg
HDPE Sheet
Primary Material Production 77-85.1 MJ/Kg 2.64-2.92 Kg/Kg
Material Processing 5.9-6.52 MJ/Kg 0.442-0.489 Kg/Kg
Water Usage 55.3-61.1 l/Kg
Open Cell Foam
Primary Material Production 103-114 MJ/Kg 4.28-4.73 Kg/Kg
Material Processing 5.39-5.94 MJ/Kg 0.431-0.476 Kg/Kg
Water Usage 216-239 l/Kg

Factory Production (from Transportation Transportation energy For final *264g - 398g CO2/km Assuming a
bulk materials to individual Assemby assuming different location diesel vehicle with 10-15L/100km fuel
components) (10-15 litres/100km)@ $1 - $1.40/ Litre) consumption
$14 - $21)/100km

Form Ply
Primary Material Production 8.77-9.7 MJ/Kg 0.358-0.396 Kg/Kg
Material Processing 0.573-.633 MJ/Kg 0.0429-0.0475 Kg/Kg
Water Usage 665-735l/Kg
Consumables

Distribution and Supply Energy consumed during packaing and Waste Packaging and materials
Chain Product Packaging packing. (Cardbord, Plaatic, steel bands etc)

Wooden palates (Soft Pine)

Primary Material Production 8.77-9.7 MJ/Kg 0.358-0.396 Kg/Kg
Material Processing 0.573-.633 MJ/Kg 0.0429-0.0475 Kg/Kg
Water Usage 665-735l/Kg

Distribution Transportation energy For final *264g - 398g CO2/km Assuming a

Assemby assuming different location diesel vehicle with 10-15L/100km fuel
(10-15 litres/100km)@ $1 - $1.40/ Litre) consumption
$14 - $21)/100km

Use
Operation (normal functioning) and Transportation Fuel costs (10-15 litres/100km)@ $1 - *264g - 398g CO2/km Assuming a
Service (maintenance and repairs)
$1.40/ Litre $14 - $21/100km diesel vehicle with 10-15L/100km fuel
Maintenance consumption
Rubbish -Recycle/Landfill
Labour, Consumables

End of Life system - (EoL) Concrete

Waste Management - Recovery and
Disposal
Recycle: Yes
Embodied Energy , Recycling 0.758-0.838 MJ/Kg
CO2, Recycling 0.0631-0.0698 Kg/Kg
Mild Carbon Steel (< 0.25%)
Recycle: Yes
Embodied Energy , Recycling 6.94-7.67 MJ/Kg
CO2, Recycling 0.546-0.603 Kg/Kg
HDPE Sheet
Recycle: Yes
Embodied Energy , Recycling 47.1-52 MJ/Kg
CO2, Recycling 3.7-4.09 Kg/Kg
Open Cell Foam
Recycle: Yes
Embodied Energy , Recycling 47.1-52 MJ/Kg
CO2, Recycling 3.7-4.09 Kg/Kg

Figure 67 MET Matrix

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1 litre of diesel weighs 835 grams. Diesel consist for 86,2% of carbon, or 720 grams of carbon per
litre diesel. In order to combust this carbon to CO2, 1920 grams of oxygen is needed. The sum is
then 720 + 1920 = 2640 grams of CO2/litre diesel.

*An average consumption of 10 litres/100 km then corresponds to 10 l x 2640 g/l / 100 (per km)
= 264 g CO2/km.

The material data collected and displayed in the MET matrix was obtained through the CES Edu
Pack 2017 software. It is important to note some of the values displayed are subjective. For
example, the fuel consumption calculations may vary considerably depending on location, time
of year, vehicle specifications and driving characteristics etc. To remedy this a range of values
were given.

Figure 68 Important calculations and justifications of the MET Matrix

Life cycle assessment summary

The HDPE and the open cell foam both have a high CO2 output per kilogram of material made in the
primary production of the material. These materials contribute a large proportion of the CO2 of the
product in the primary production.

The transportation of materials for producing parts as well as for packaging and delivery has a large
impact of the carbon footprint of the product. Using all local materials would reduce the distance all
materials would need to be transported, meaning less carbon i emmited due to transport. For
example, the open cell foam could be sourced in geelong or melbourne rather than from NSW.

All of the materials in the design are recyclable as shown in the MET matrix, however, the open cell
foam and the HDPE sheeting both require large amounts of energy and emmit large quantities of
carbon to succesfully recycle into a useable product. Unfortunately, whilst all materials used are
recyclable not all materials are likely to be recycled in Australia. This is because of the large
quantities of energy needed to recycle some materials such as open cell foam and HDPE.

7.3 Design for X principles

Design for Assembly:
The products are all modular. Each pillow track has the same base dimensions so the pillows are
interchangeable within the foundations. This also allows for the maintenance or replacement of the
pillow track.

All the hand rails are variants on the basic hand rail; the basic shape is the same to avoid unnecesary
complexities in the manufacturing process

All the hand rails have the top metal section, which is exactly the same as the basic hand rail,
meaning only one type of top hand rail needs to be created. This makes the production of those rails
much faster.

The foundations are designed to have holes to join the hand rails to, which are the same for all
designs of the hand rails, meaning faster production and the option to replace the hand rails with
different ones midway through the products life.

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The modularity of the products means that the production of these designs will be much faster, as
the machines do not need ot be adjusted for each design, which also makes the production cheaper.

Design for Safety:

The hand rails extend past the ends of the pillow track allowing users to grab the hand rails prior to
mounting the track.

The pillow tracks do not have rounded edges (when seen for the front) that could allow feet to be
trapped between the pillow and the walls/and rails.

Design for Logistics

The materials and productions of the equipment are all sourced and manufactured locally where
possible to keep the logistics of manufacture simple. The foundations are cast at the site to avoid
problems such as needing an exactly level hole in which to place the concrete, where a foundation
cast at site can accomodate small undulations.

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________________________________________________________________________________________________________________

7.4 Production cost estimates

Cost summary table

Cost Summary Table

Item Description Quantity Manufactured Location Price (GST inc.) Shipping/Delivery Total Cost

Steel Hand Rails Mild Steel, 5.4m x 48mm x 4mm 2 Dandenong VIC $ 102.46 Pickup $ 102.46

Powder Coating Professional job, includes paint and labour 1 N/A $ 100.00 $ - $ 100.00

Aramid Fibre Material Aramid Fibre Plain 1000mm – 170gm/m² 3m² Cardiff NSW $ 96.50 $ 15.00 $ 111.50

Rubber Sheeting 700mm wide/per metre, 9mm thick 2.7m Armidale NSW $ 38.61 $ 40.00 $ 78.61

Foam Type 25 - 50, custom cut 1 Brisbane QLD $ 538.00 $ 219.00 $ 757.00

Rock Climbing Holds 21 Piece Set 1 Armidale NSW $ 92.00 $ 18.00 $ 110.00

Concrete Plain concrete, standard finish 0.75m³ Geelong VIC $ 60.00 $ - $ 60.00

Steel Pipe Bending Labour/Machining cost 2 Geelong VIC $ 200.00 $ - $ 200.00

HDPE Polyethylene Sheet 3m x 1.5m x 3mm 1 Melbourne VIC $ 209.64 $ - $ 209.64

Onsite Install/Assembly Labour: 8 hrs, $30 per hour 1 Geelong VIC $ 240.00 $ - $ 240.00

Total Cost of Production/Assembly: $ 1,969.21

Table 9
Jack Gregory: SED304 Product Development, 2018, Trimester 1
________________________________________________________________________________________________________________

Cost analysis estimation

The cost analysis table included the cost of local labour valued at approximately $30 per hour, which
was required for all the hydraulic bending and coating of the tubes, along with the cutting and fitting
of the rubber coated aramid fibre to the pillow track. All costing is assuming local labour as all
materials and further outsourced production, such as the bending of the mild steel tubing will be
sourced locally in Victoria or new south wales. The foam is relatively expensive due to the distance it
needs to be transported and the high cost for the large amount required. All assembly will also be
conducted locally which is cheaper for the very low volumes of product that are expected to sell for
the first year (10 units), compared to overseas labour with the addition of the shipping costs. Some
assembly such as the construction of the concrete base will be conducted on the site where the
equipment is being installed.

Break even analysis

The projected first year sales of the walking track is 10 units. At $1,969.21 to make the product and a
retail price point of $8000, the profit in the first year is expected to be $60,307.90.

The purchase of a powder coating gun and a hydraulic tube bender valued at approximately $100-
$500 Coating.com.au. (2018) and roughly $4,000 to $8000 Anon, Metalworking
Machinery. Machines4u Magazine respectively would lower the ongoing costs due to no longer
needing to send the tubing to a professional manufacturer and instead hiring labour to complete
those tasks as part of the balance walkway company. This however, is only a viable solution if many
units are expected to sell, which can be gauged more accurately after the first year’s sales.

8 Detailed design and engineering

8.1 Failure Modes and Effects Analysis

 RPN
Process Potential Failure Potential Class Potential Cause(s)/ Occurance Current Recommended Action(s) Action Results

Severity

Occurance Rating

Detection
Function Mode Effect(s) of Mechanism(s) of Class Process

RPN
Failure Failure Controls

Severity

Occurrence

Detection
Jack Gregory: SED304 Product Development, 2018, Trimester 1
________________________________________________________________________________________________________________

Rubber Aramid/rubber Weakening of 3 Minor Corroded/worn bolt 3 Unlikely None 7 Nil - - -

sheet rip sheet hole becomes sharp,
repeated stretching 63 63
Metal rails Metal surfaces Metal surfaces 2 Insignificant Powder coating worn 9 Very Likely None 2 Nil - - -
could corrode could corrode off through extended
use 36 36
Pillow Pillow fills with Reduced 8 Very Hole or leak between 3 Unlikely None 3 Inspection of rubber sheet joint to 8 2 2
water lifetime of harmful rubber sheet and securing ring
product securing metal ring 72 32
Walls Wall collapse User fall from 10 Catastrophic failure of securing 4 Remote None 5 For load bearing walls, such as rock 10 1 2
height bolt/mechanism climbing wall, multiple additional securing
joints should be used. Inspection should
200 include inspection of joints and bolts 20
Walls Rock climbing grips User fall from 10 Catastrophic Failure of securing 6 More Inspection 4 Tamper proof bolts to be used for grips, 10 2 3
could height bolt, bolt has been Plausible of grips inspection should include all grips and
break/fall/dislocate tampered with, bolt securing bolts
has come loose, grip
has broken, or worn 240 60
Rubber crumb Rubber crumb User fall 10 Catastrophic Failure of glue 1 Improbable Inspection 2 Further research into correct glue, or 10 1 2
becomes loose possibly a cap at ends of rubber crumb to
20 secure it in place 20
Foundations Foundations shift Could cause 3 Minor Earthquake, or slower 1 Improbable None 10 Nil - - -
or crack degradation of movement of earth
pillow to
speed up, due
to water
leaking into
foam from
below 30 30
Foundation Foundation not set Weakening of 8 Very Poor weather at time 8 Probable None 3 Delay casting at site until weather is fair, 8 1 1
correctly foundation, harmful of setting, incorrect staff concrete formation training,
increased concrete ratios inspection of foundation after it has set
instability of
rails and walls 192 8
HDPE weathering of walls Slight warping, 2 Insignificant Poor surface finish 3 Unlikely Inspection 1 - - -
Sheet/walls discolouration and
replacement 6 0
 Jack Gregory: SED304 Product Development, 2018, trimester 1

Chains Weld joint/chain User fall 10 Catastrophic Poorly welded joints 2 Very None 10 Inspection of weld sites for visible 10 1 8
link failure Unlikely corrosion, ensure staff properly trained.
Further research into max loading
200 capacities of weld links in chains 80
Table 10

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Implementation of results to
Design
Improvements include:

• For load bearing walls such as the chain lattice and the rock wall, multiple new joints that
secure the wall to the foundation should be used, to ensure the walls are stable even in the
event of one joint becoming broken. Two new joints over the length of each wall should be
added to all foundations to ensure the walls are still interchangeable. The additional joints
can be covered with a steel cap or similar device when not in use. For example, if the
equipment only has a hand rail installed, the extra joints are unnecessary.

• Tamper proof bolts should be used for rock climbing grips and all other joints

• A lip on the top of the edges of the securing ring for the rubber sheet, to assist the glue to
hold the edges of the rubber crumb in place.

• Staff training to include protocols for the safe set up of the foundation

The inspection process that should be undertaken quarterly should now include:

• Inspection of rubber sheet joint to the securing ring, to ensure no wear of the sheet.
• Inspection of joints and bolts that secure the hand rails and climbing walls to the
foundations.
• Inspection should include all grips and securing bolts for the rock climbing grips
• Inspection of foundation after it has set, to ensure that it meets quality standards
• Inspection of weld sites on the chain lattice for visible corrosion or wear
Jack Gregory: SED304 Product Development, 2018, Trimester 1
________________________________________________________________________________________________________________

8.2 Detailed design and engineering resolution

The final design is a walking track that deforms as the user walks across the track. The hand rails also
serve as attractions for younger users, to aid in the interaction between users.

The design will have a foundation that will be cast at the site of construction. The foundation will be
cast to include joints holes, where steel tubes can be inserted for the insertion of the hand rails. The
steel tubes will be inserted during the casting process. The steel tubes along with the hand rails will
have a pre-drilled hole where the joining bolt (See full list of fasteners below) can be inserted.

Figure 69 The Steel tubes used for the joints to the hand rails will be cast into the concrete

Figure 70 The joints between the foundation and the hand rails will be a steel tube protruding from the foundation. Note
the tamper proof bolts through pre-existing holes in the tubing.

Note: The chamfer on the HDPE wall allows adequate space to access the bolts in the joint.

The pillow will be attached to the foundation via an adhesive. The aramid and rubber sheet layer will
then be laid over the top of the foam, before being bolted in place through a securing ring, that
surrounds the whole pillow. The securing ring provides a much larger surface for the tension forces
to be dissipated, which will decrease the probability of tears or wear at the point where the rubber is
pierced by the bolt.
Jack Gregory: SED304-Product Development, 2018, Trimester 1

Figure 71 The pillow will be attached to the foundation through a multilayered process.

Figure 72 The securing ring provides protection against the edges of the rubber sheet ripping or wearing. It also- as the
name suggests, secures the aramid and rubber sheet.

Once the securing ring has been installed, a rubber crumb coating will be glued to the top of the
foundation, to cover the joints between the securing ring and the foundation. The rubber crumb,
similar to that found in playgrounds, will provide a soft surface for users to walk along, prior to
mounting the walking track. It also reduces the severity of any injuries due to falls on the apparatus.

Figure 73 Rounded edges and rails that are longer than the pillow track aid the usage of elderly people

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The hand rails extend past the pillow to allow users to grasp the rails before they mount the walking
track. The rails also have rounded edges to reduce the severity of any injuries due to knocks or
bumps on the corners of the rails. The rails have been sized in accordance with the findings of
observations of the sizes and diameters of common railings, and those that are specific to disabled
or elderly users, such as those in disabled bathrooms. These sizes should provide the best support
for elderly users. The railings used are 1.34 m tall and have a diameter of 54 mm.

Figure 74 Common hand rails and easy access bathroom railings were measured to find the best suited
dimensions for elderly users.

All sides and pillow tracks of the design are modular, and the buyer has the option to chose which
elements they pick, which can include a different side on either edge of the equipment.

Figure 75 All sides and pillow tracks of the design are modular

The pillow track is removable in order to accommodate maintenance or the replacement of the
pillow. The securing ring is removed before the foam and rubber sheet is removed. There are
currently two pillow designs; the rounded edge pillow and the ramped pillow.

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Figure 76 The rounded and ramped pillow tracks are modular and can be replaced

The hand rails are all modular and include three varieties.

The basic hand rail. The hand rail is a single powder coated steel tube that is bent using a hydraulic
steel tube bender.

Figure 77 Basic side

The chain lattice. The chains will be welded together and to the hand rail to form the lattice.

Figure 78 Chain lattice side

The rock climbing wall.

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Figure 79 Rock climbing wall side

The rock climbing wall has 15 rock climbing grips attached to encourage younger children to climb
across the wall as other users walk along the pillow track.

Figure 80 Rock climbing grips

The rock climbing grips and the wall are brightly coloured to attract the attention of younger
children who will most likely be supervised by older people, who may then use the equipment with
their child. The grips are bolted to the HDPE sheet via tamper proof bolts which insert into holes in
the grips. Large grips have been chosen to allow young children to easily climb across the wall.
Adequate grips are also placed along the bottom of the wall to ensure that children have an easily
available foot hold when they chose to mount the wall, whereas, hand holds are slightly more scares
to provide a greater challenge.

The rock climbing wall has steel brackets which are bolted in place and attach it to the hand rail.

Figure 81 Steel brackets attach the HDPE wall to the hand rail.

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Commercially Available Products Utilized

Commercially Specifications Quantity Stockist Use in Product Picture of Item
Available
Product

Tamper Proof D: 10mm 8 (includes Bunnings Fastens hand rail to

Bolts barrel and mount in
L: 60mm
bolt) foundation
(Security Sex
Bolts)

Figure 82 FASTENAL (2018).

Tamper Proof D: 10mm 24 Bunnings Fastens HDPE plate

Bolts to hand rail
L: 20mm
(Security Sex
Bolts)

Figure 83 FASTENAL (2018).

Anka Bolts D: 6mm 18 Bunnings Fastens the ring

flange and aramid
L: 100mm
rubber to the
foundation thereby
securing the foam
pillow in place

Figure 84 Mitre 10 (2018).

Tamper Proof D: 8mm 21 Bunnings Secures the rock

Bolts climbing pieces to
L: 14mm
the HDPE wall
(Security Sex
Bolts)

Figure 85 FASTENAL (2018).

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Coloured Soft - 1m² Rubber Covers the

Fall Rubber Crumb foundation, ring
Crumb Industries flange and
Aus surrounding area

Figure 86 Safe Play Surfacing LTD (2018).

Galvanised 8mm 32m Bunnings Chain for hand rail

Steel Chain climbing wall

Figure 87 Bunnings (2018).

Table 11

8.3 Simulation analysis and design modifications:

Figure 88

The above figure displays the simulation setup with the base of the foundation being an encastre
(fixed) boundary condition and a uniformly distributed load on each shoe simulating the weight of a
person.

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Figure 89: Meshing of Assembly.

The mesh characteristics include the Number of nodes at 20121, the total number of elements of
12007 and the number of degrees of freedom DOF calculated to be 54672.

Figure 90:Von Mises Stress

The above figure displays a maximum Von Mises stress of 2.5 MPa consistent with the applied loads
and associated area.

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Figure 91:Displacement (mm) with 200kg person.

The maximum displacement of 200mm/20cm occurred with a maximum simulated 200kg person
displayed in figure 4 associated with the green colour. The maximum displacement seemed to occur
in the shoe itself. The More accurate bonding option was used in this study between the rigid
polyurethane foam and the uniformly loaded shoe sole. Deformation was obvious during this
simulation however; these results will be reduced given that the aramid reinforced cover was not
included which will act to stiffen the foam along with a reduced load.

Simulation findings and implementation

The height of the pillow track can now be ascertained from the results of the simulation. As the
maximum deformation was 20cm for a 200-kg person, the depth of each pillow track should be 24
cm to avoid wasted material. The cut-out depth of the foundation, where the pillow track sits can
be adjusted to be 4 cm deep, as the maximum deformation of the foam should not lower the users
foot to below the original “ground” level. Note: The rubber crumb will increase the height of the
ground level, however, this can also deform under the weight of the user, so the depth of the rubber
crumb should be ignored in this instance.

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Figure 92 The cut-out hole in the foundation has been adjusted to 4 cm deep due to the simulation findings.

Figure 93 The height of the pillow tracks has been adjusted to 24 cm

9 Final Design

9.1 Final prototype

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Figure 94 The prototype features the ramped pillow and the rock wall and the basic hand rail on the other side. As the rock
climbing grips are too small to successfully 3D print, blue tack has been used to simulate the grips.

Figure 95 The rock wall and chain lattice sides allow multiple users to interact with each other and the apparatus at the
same time

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Figure 96 Users' feet sink into the ramped pillow track, to provide an unstable place for the user to walk along.

Figure 97 The rounded pillow track provides a stair like entry to the pillow track, to test users leg strength and
stability

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Figure 98 Children can climb along the rock wall and interact with users of the pillow track at the same time

Through the prototyping stage, the design has evolved to include better joints for the railings. The
rails will no longer be directly slotted into holes in the foundation, but slotted and then bolted into
steel tubing that protrudes from the foundation. The tubing allows the rails to be bolted in place
with tamper proof bolts. The tubing means the rails can be removed for replacement with a
different model or for maintenance.

Figure 99 The tubing allows the bars to be removed and replaced, but only by a specialist removalist or contractor.

9.2 Final communication and visualisation

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Figure 100 The user can walk across the pillow as it deforms around their feet, providing a more challenging balance
situation. Note the user sinks into the pillow.

Figure 101 A close-up of the joint between the foundation and the side hand rail. Also note the securing ring holding the
rubber/aramid sheet over the top of the foam pillow.

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Figure 102 The user has the opportunity to gauge the softness of the pillow when using the ramp stage of the track, before
they mount the flat, softest section of the pillow track

Figure 103 The full product, featuring the rock wall and basic rail sides

Figure 104 A view of what the equipment will look like once it has been installed.

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Figure 105 Another view of the final product. Note the darker grey ground surface is a rubber crumb, which provides a soft
surface that reduces the likely hood of injury if a user is to fall.

Figure 106 The foundation, now has three steel tubes on each side.

The foundation now has three steel joining tubes on each side. The extra joint will provide greater
stability for the rock wall side, as it is load bearing. This change was made after the FMEA process’s
recommendations.

The outside “walls” of the foundation have become shorter, after the simulation determined the
maximum deformation of the foam. The walls are now only 4 cm higher than the rest of the
foundation. This saves material of the foam and of the concrete foundation, as neither the foam nor
the foundations “walls” need to be as tall. This adjustment saves concrete as well as foam. Note; The
blue section below represents the foundations “walls”. The “walls” help secure the foam layer in
place and prevent it slipping horizontally.

Figure 107 The blue section in this diagram represent the foundations' "walls"

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Figure 108 The cut-out section is now only 4 cm deep

The new foam layers of the pillow track have been altered to minimise wasted material. The new
depth is 24 cm, with 4 cm being in the vertical section of the ramp (The end of the ramp).

Old New

24 cm

4 cm

Figure 109 The old pillow track on the left, and the new track on the right

Old New

Figure 110 The new rounded pillow on the right, and the old rounded pillow on the left. The depth dimensions are the same
as the ramped pillow track. I.e. 24 cm deep, with 4 cm below the top of the foundation.

The buyer has the option of three different sides; the basic hand rail, the chain lattice and the rock
climbing wall.

Figure 111 Chain lattice side

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Figure 112 Rock climbing wall side

Figure 113 Basic side

9.3 Technical documentaition

Please see appendix 8.

10 Conclusions

10.1 Aims and objectives of the final design

The final design is a walkway track for elderly users to improve their strength, stability and balance.
The balance walkway provides the opportunity for elderly users to be challenged in a safe
environment, where they can easily support themselves using the handrails beside the track. Unlike
other existing products in the excersise equipment market, the balance track provides the
oppurtunity for users to not only test their balance whilst stationary, but also to improve their
balance while they walk forward. This provides a key improvement to current products as it is much
more likely to prevent falls as users can improve their stability on both feet or each foot individually.

The balance walkway also provides a fun place for younger users to play, which it is hoped will
encourage elderly guardians to use the equipment as well. Children can bounce walk or run on the
walkway, or they can climb across one of the feature walls, such as the rock climbing wall or the
chain lattice.

The balance walkway provides a safe and fun place for children and adults alike to play or work on
their balance and proprioception.

10.2 Evaluation of the final design

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+ Positives - Negatives
Strengths Weaknesses
Internal Factors

• Modular design, allows for customer choice in side • The rubber crumb
walls and pillow and the option to replace old walls needs to be removed
with new walls with a different design. before the pillow can
• Attractive to younger users due to bright colours be changed
and fun equipment such as the rock wall • Could be mistaken
• Safe design only for playground
• The product has a long life span of 10+ years, equipment and not
which will allow customers to justify the upfront used by elderly
cost • The equipment has no
• The balance walkway is the only existing balance cover from rain, so
type equipment for elderly people where users can when it is installed
challenge their balance whilst walking-not standing outside from cover,
still. the surface could
• The foundation is cast on the site, which eliminates become more slippery
the need to crane the foundation out of a truck, when wet
and the logistics of transporting the heavy • At $8,000 per unit, it
foundation. It also allows the base of the hole, may be too expensive
where the foundation will sit, does not have to be for many smaller
perfectly flat, as the concrete will flow over the centres or local
rough surface. councils.
• The foundation needs
to be cast at the site,
which limits the
instillation to days
where the weather is
clement
Opportunities Threats
External Factors

• The product can have many new side walls and • More diverse
pillows as these features are modular companies could make
• The equipment could also be used in other settings products similar to the
such as playground or it could be placed in areas balance walkway, or
where the target demographic is children; not sell similar products of
elderly users. lesser quality for a
• It could also be adapted to be used in gymnasiums. cheaper price
As it is the only walkway where the user is • The local governments
challenge whilst they walk, it has potential and councils may not
applications in different forms as gymnasium have adequate
equipment, in addition or as a replacement for funding to purchase
traditional stationary balance equipment. the equipment,
• Australia has an aging population, which will particularly in times of
provide greater pressure on local councils and care greater political or
facilities to provide adequate equipment for economic pressure.
elderly people to exercise.

Table 12 SWOT analysis table

10.3 Further work

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The design has the potential for many more modular components to be added, particularly in the
addition of new side wall hand rails that are exciting for children or functional for other users. The
walkway itself could also be added to, so that there are options for different levels of softness, or
multiple layers, such as steps up and down.

The equipment could be made so that maintenance or replacement of particular components is

simpler. The current design requires the removal of the rubber crumb coating above the concrete
before the tamper proof sex bolts can be removed in order to take the walkway out. New designs
could eliminate the need to remove and most likely destroy the rubber crumb in the process.

The foundation needs to be cast at the site, which limits the instillation to days where the weather is
clement, therefore, new designs could potentially include a lighter foundation that could be made
off site and would not need to be craned out of a transport truck. This would allow the equipment to
be installed in all weather.

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Bunnings (2018). Pinnacle Hardware 8mm (5/16") Galvanised Chain - Per Metre. [image] Available
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Shade & Sail Innovations (2018). Shade Sails Perth. [image] Available at:
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Smithweld metal bending rolling curving, Melbourne. (2018). Smithweld metal bending rolling
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Synergy Scaffolding & Access Equipment. (2018). Galvanised Steel Scaffolding Tubes | Synergy
Scaffolding & Access Equipment. [online] Available at:
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300mm/?attribute_tubelength=1.5M&keyword=&gclid=Cj0KCQjwrLXXBRCXARIsAIttmRPEstFe1iQN0
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Trojanfibreglass.com.au. (2018). Aramid Fibre Plain 1000mm – 170gm/m² | Trojan Fibreglass Online.
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1000mm/ [Accessed 6 May 2018].

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http://www.uncarvedblock.com.au/products/twenty-one-set.html [Accessed 7 May 2018].

Appendices
Appendix 1 Full interview transcripts ................................................................................................... 87
Appendix 2 Observation ....................................................................................................................... 93
Appendix 3 Gantt Chart ........................................................................................................................ 98
Appendix 4 Composition Sketches........................................................................................................ 99
Appendix 5 Perceived satisfaction of Needs....................................................................................... 106
Appendix 6 Needs-Metrics Matrix ...................................................................................................... 107
Appendix 7 Inspiration Board ............................................................................................................. 109
Appendix 8 Technical Documentation ................................................................................................ 110

Full interview transcripts

Appendix 1 Full interview transcripts

Interviewing
12/3/18

Tell us about yourself? What is your background in working out?

Alright. My name is __. I’m currently working at North Melbourne football club as one of their
strength and conditioning coaches. My background in terms of why I got into this industry probably
stems from when I was just finishing year 12 and going into my undergrad in exercise sports science

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which kinda transitioned between the two where my passion for fitness came about. So, going
through year 12 I was very skinny weighed low 70’s [kg] hadn’t really been to the gym at all until a
mate introduced me to it. And it was from that session alone that stemmed my passion to continue
working out. It was just an interest behind the different movements the different muscles and how
much you could develop from just a consistent training program. So that continued pretty much
through the latter half of year 12 and really started to evolve through my bachelor [degree]. When I
was at university I would go to the gym pretty much every night after I’d finished class when other
people were getting drunk, I’d be in the gym. That was my avenue of fitness, that was my passion. I
really started to delve deeper into the why’s and the what’s of resistance training and how much
further you could take it. It would have been during my last year of the bachelor [degree] where I
had a conversation with a guy who worked at the gym and he talked about the masters [degree] in
strength and conditioning and the university course in WA. I was really intrigued with what he was
talking about and the prospective jobs that were available for people who’d gone through the
course previously. That night I looked up the course and all the subjects were really, really appealing,
all the content and the way it was set out. I was really confident with going down that line, with my
felid of choice, so I finished the bachelor enrolled in that course, was lucky enough to be accepted
and enrolled into the Master’s [degree] in Strength and Conditioning which then opens up a whole
new playing field of ideas, different passions that evolve from that course that really tailor your
thinking and interests in S&C.

My personal lifting has changed a lot over the time. You start with a lot of machine weight, because
that’s what you’re used to and that’s what you’re told to do and then you start to experiment with
some free weights. And then you start to home in on what you want to achieve. My goal back then
was to develop my strength. So, I went down the pathway of building squat, building deadlift
building bench press building overhead press; the four big lifts. That was two, three years of refining
those lifts to the point I was doing a novice power lifting competition at one stage cause I was quite
proficient at my lifting. It’s funny how you go through these ebbs and flows in your passion. That
sorta phased out I went down a different pathway into more functional training. I started to dabble
in that. Tried out some different ideas. Now I’m currently into a more strength training mindset.
Going back into some old training blocks that I’ve come up with a few different tweaks. You’re
training evolves over time in response to what your current interests are and how your body
responds and changes; as you get older your recovery gets slower, you learn a lot more and you
become smarter in your training. You spend less time in the gym, when back in the uni days you
were under the impression you had to spend two hours in the gym every night to achieve something
when you can quite comfortable spend less than an hour and achieve the same end result or better.
You just become smarter with your choices.

Have you dabbled with where you have exercised? Have you always been in the gym; have you used
park equipment, have you done stuff at home?

Absolutely. Like it almost becomes you know. You try to break out of the mindset of being solely in
the gym. You wanna try and open up the platform you work off. That might be just going to a park in
the neighbourhood and it challenges your thinking as to how can I make a session out of what I have
in front of me, it gets you really creative in the ways you go about your movements. You can do a full
body session quite comfortably off minimal equipment. You could go to the beach and do a body
weight session; push-ups, sit-ups, squats, lunges, using the gradient of the sand dunes leading into
the shore. So absolutely, there’s a number of different ways you can manipulate your session based
on what you have. You just have to be creative with what you’ve studied, what you’ve seen and

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blend those together to have a really nice output for your session. I’ve used parks, I’ve used a branch
on a tree for chin-ups and muscle ups. Up in Sydney there’s some really good exercise stations that
they have; every one kilometre the have a different exercise station, so you pretty much follow a
running track, you do a stop and spend maybe 10 minutes at that station and then you continue on.
And every station has a different element that you target on your body. So, you’re limited by your
imagination by what you target in those sessions because in the gym you’ve obviously got other
people around you, you’ve got heavier weight, you can really crack in and have a good session. But if
you’re at the park at your own it’s a completely different setting so you’ve really got to drive yourself
through it and think outside the square with what you can do- not always think mainstream.

What do you think is the limiting factor for park equipment and outdoor exercise? How would you
improve it?

It probably stems from what I saw up in Sydney when I’ve been up there before. They’ve done it
really well with how they’ve set up their exercise stations. They have really good flooring so its
normally some sort of rubber flooring, it’s not tan bark like a normal playground. The bars are really
secure so they are not unstable when you are hanging off them. And every station has a theme to it,
one station might have a pulling theme, another might have a pushing theme, one might be some
sort of lower limb theme and its set up really well so every station is balanced. Even in St Kilda they
have a really god outdoor gym that is completely made up of bars, different planks that are on
different inclines for core work. They’ve got bars that are really low to the ground that you can do
push ups off of, or split squats. It’s got bars that are quite high for chin ups or hanging leg raises. It
has been done really well. And again, it’s got a proper rubber flooring, so it is stable and safe. I think
that is probably the limiting factor. It is hard because you’re looking at a playground that is designed
for kids not outdoor gym enthusiasts. If they were to tailor it to more that group (outdoor gym
enthusiasts), different themes for each type of lift would be appropriate. That way when people
start to look at it they can start to see what each station is designed for, rather than, where do I
start, I don’t know what to do, let not do anything. So, it’s about taking the movements you see
inside the gym and replicating them in an outdoor setting on a playground. If that makes sense haha.

What do you think would be limiting factors to people who might be rejecters of outdoor exercise
equipment that aren’t power users, that might be older, might be small children or just inactive, why
do you think they wouldn’t participate on outdoor exercise equipment?

I think for a lot of those sub groups it’s about the outside perception, about what others will think of
them in a gym setting. Let’s say they’re doing a bench press for example, they might be doing so
with form that’s not so technically proficient or light weight. And it is the outside perception of what
do others think of me – I might be a guy in my mid-twenties but I’m only putting up 40kg on the
bench press and someone beside me of the same age might be doing 100kg. It is the feeling of what
do they think of me, the judgement that’s really a big one. If you go down the line of women, who
may be carrying a bit of extra weight, if they are on a treadmill and beside them is someone that is
half their size, there is the perception of oh what do people think of us as a comparison. So, I think it
is pretty sad that, that is where it is at with public perception. And it no doubt carries over to outside
settings, if you are on a playground or particularly an outdoor gym a lot of the guys will train with
their shirts off, to show off the rig. But it is more of that bro mentality of look at me I’ve got a six
pack, well defined upper body. So, if someone comes along who may be skinny or have pale skin,
he’s not going to want to take his top off or workout because he is going to feel very insecure
because of the way these other people are presenting themselves. I think that is the biggest limiting

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factor that is the outside perception. If you were to take away the other people and that person was
working out on their own it would be a completely different story. They would probably be having a
really productive session and they would walk away saying to themselves, that was really enjoyable.
But put them in there with 3 other guys who are quite well built, who have a pretty good size, a
good physique, that person wont workout to the intensity they probably would have if they weren’t
there. So, for me the number one thing is that outside perception. Going forward, it’d be about
designing equipment for different groups. Designing a station for beginners or people who are new
to lifting, then the next station might be for more advanced lifters. But having them separate and
having a sign upon entry to the station explaining the rules and more importantly addressing,
keeping the clothes on, respect other users and put the ego aside because it’s a public gym it’s not a
private gym. So, to be a combination of designing stations that are separate to address the different
needs and then a clear sign out the front with a few dot points addressing those main issues.

Are there any exercises you think could be particularly beneficial to people who are inactive?

For me it’s about addressing the 4 pillars of movements. For me that is doing some sort of
squat/lunge movement, doing some sort of hip hinge movement, and then a horizontal push and
pull and a vertical push and pull. Targeting those four pillars you will build a really good foundation
with some core work and that will address any glaring weaknesses in people that are relatively
inactive. Because it will generally show any asymmetry’s. Particularly the lunge over the squat
because it is unilateral in nature so will show any differences between left and right.

……………………………………………………………………………………………………………………………………………….

Interview 2:
Trish, Age 76

I'll start by just asking some basic questions. So yes how old are you?
I’m almost 76.

And currently do you do any exercise, Intentional or not?

Yes, I go to the gym three or try to go three times a week.

And do you participate any classes or do you just do training with a trainer? like what do you do at the
gym?
Well at the gym, you are assessed you are written out a program and you follow that for so many
weeks and periodically your program is reassessed and but not individually supervised

Yeah?
There are people there supervising and you are given a time slot so not everyone turns up at the
same time

And how have you found being a gym member?

Well at this gym its very good because it is a gym specifically for people with disabilities and older
people so you're all the same, well you’re not all the same, but you don't have your mad gym
people.

Yeah. So, it's a bit less intimidating you would say?

It's far less intimidating than a general gym

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And if your current team was to run some any outdoor group exercise classes. Would that be
something that you'd consider signing up to?
Well I don't know. My understanding is that it's very vigorous. So, no I wouldn’t be interested in that,
but I would consider outdoor exercise

Do you have any experience with that outdoor exercise in public places or using existing fixed
equipment or anything like that?
I took part in a study on exercise in the elderly which was an outdoor area at the back of a hall
between a nursing home and a day-care centre.

Can you tell me more about that study?

It was done as part of a PHD for a lady called Myrla Sales

Yeah? Focusing on exercise and the elderly?

yes, and Improving health in them.

How did you find your participation in that?

It was really great fun, and it certainly made a difference to my balance and probably strength and
probably cardio fitness as well

And the sort of stuff you did in that study would that be stuff that you would continue on your own?
If it the equipment that’s we used in the study was there to be used then I would, Yes

In terms of specialist equipment, I suppose, what do you think would encourage you the most to use
it? like is it being designed to suit your specific needs or is it, its location you know is there anything
specific that would help?
Well location depending on where it's located would influence my decision to use equipment like
that, and the fact that it was specifically designed for improving different aspects like balance and
strength

In the sense of its location, if it was in middle of a regular park with a running track running past and
that sort of stuff. Would you go for a walk down there and an exercise there or would you feel
comfortable there or not? thinking back to your experience the gym feeling sort of included and feeling
like that was a good place for you to exercise?
Yeah, I think that I would encourage friends of mine to go with me. Yeah and take part and join me
using the equipment, but I would probably go myself anyway of that was available, I would use it.

So, a couple things, last couple things going back to your experience of that study you mentioned
improving your strength and balance are they the things that you think you'd benefit the most from
improving or is it your flexibility? What are the things that you think would help you most in your day
to day life?
Well flexibility strength balance and cardio

And where in your life do you think you experience the benefit?
Well just in your ordinary house work and going to the shops walking to the shops and carrying your
bags home and just walking around the street you're less likely to trip and fall if you are improving
your balance

So, would you say after you found that improvement would you have been more likely to have walked
to the shops to pick up some bread and milk than in the past you might have driven or?
No, access to the shops the distance to the shops influences that.

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Yeah okay.
Yeah if it's within reasonably easy walking distance I have always walked. doing this study also
encouraged me to get back involved at the gym and regular exercise.

Ok So with that study was that before you were going to the gym and is that sort of got you started
exercising
I have attended the gym at different periods over the last 20 years. But because of injury and health
problems I had stopped and going to study, taking part in this study encouraged me to go back and
take part in regular exercise.

OK thanks Trish, that’s our time up I will talk to you if I need anything more, thanks.

No worries thanks.

……………………………………………………………………………………………………………………………………………

Interview 3

Date: 11/03/2018

Good morning thanks for talking with me.

That’s ok.

So as part of a project for one of my classes at university we have to design outdoor exercise
equipment; part of the process is to gather information from a broad range of possible users.
I’m not sure I’ll be able to help but you’re welcome to ask anything you like.

Can you tell me about any experiences using exercise equipment?

I’ve never used any exercise equipment, growing up I was never interested in that kind of thing. I did
play a lot of table tennis though. I used to represent the state back in my day.

Do you play tables tennis anymore?

No, I’m too old for that now I can’t stand up for long, I have Peripheral neuropathy in my feet which
causes a bit of problems. It kills the nerves in your feet that’s why I have orthotics and use a walking
stick when I go out.

oh ok, are there any exercises that you do to cope with that?
There’s several exercises my doctor recommends but they don’t help. I usually like to walk up and
down the steps at least 5 times a day and also sit down and stand up out of my chair, that gets the
blood flowing, I always work on using my muscles to do anything. I’m almost 84 now you know. I
also go to the shops on a regular basis for food and anything I need, this means I have to walk to the
bus stop, around the shops and back again usually with my roller full of food. I’m usually buggered
for the next few days. Fortunately, I haven’t been having any falls lately but I’m always really careful.

Yes, you’re doing really well. Do you use any kind of equipment in day to day activities? And do they
help?
The only piece of equipment that really helps me is my walker and walking stick which is good
assistance when I need it. I use things around the house, usually I stand on one foot while holding

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the back of my chair it’s meant to help me with balance. I have been told to put weights around my
ankles and lift my legs up one at a time while sitting down but I don’t do that.

Ok well that’s good. So, I know you have grandchildren can you tell me how many?
Yes, I have 6 grandchildren and 4 great grandchildren.

If you think back to when you looked after grandchildren, were there any activities you
enjoyed doing together?
oh, I don’t know, I used to baby sit but that was a long time ago, I don’t see my grandchildren and
great grandchildren all that much. I am going up to Dubbo to see my great grandchildren soon that
will be good. Because of the distance I'm not interacting very much with anyone actually. We used to
walk and spend a lot of time in the backyard and around the park that was really good getting out in
the sun. I also had alpacas on some land nearby so we would go and visit them occasionally.

What kind of things did you do in the backyard and the park?
We’ll, I used to do a lot of gardening, and I would usually be in the garden while my grandchildren
were doing things around the house, riding the old scooters or playing with the dogs. I did a lot of
knitting and spinning as well but that isn’t really exercise, I also did lots of crafts but most of these I
can’t do anymore because of arthritis. The local park was good to get the kids out of the house when
they came to visit; I would just watch them until they had enough

Was it a nice park?

It was good I think a couple of swings and a sand pit not like some of the one’s you see today.

Ok well thanks for doing the interview I think that’s all I need.
……………………………………………………………………………………………………………………………………………………………

Appendix 2 Observation

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Observation

Figure 116 A power user using park equipment for a Figure 115 A majority user using the
Figure 114 A power user stretching their
one-legged squat equipment
spine

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Figure 118 A majority user using the equipment. Notice the sizing of
the equipment to encourage only part of the foot to be in contact
with the equipment at any one time
Figure 117 A power user stretching Figure 119 A power user using
the spine after a workout monkey bars for chin-ups

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Figure 121 The grandfather holds the boy’s hands

for the child’s stability
Figure 120 Note the way this user grips the bar due to an
injury on the middle finger

Figure 122 The grandfather uses his foot to steady the “Surfboard

Figure 123 The grandfather prevents the child from

falling off the back of the equipment with his body

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Figure 124 A man using the monkey bars for a gymnastic

Figure 125 A lady holding her purse, handbag, and a shopping manoeuvre
basket.

Figure 126 A woman pushing a trolley through a supermarket.

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Appendix 3 Gantt Chart

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Appendix 4 Composition Sketches

Composition Sketches
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Figure 127 Composition sketch

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Figure 128 Composition sketch

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Figure 129 Composition sketch

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Figure 130 Scale and user interaction Sketch

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Figure 131 Scale and user interaction Sketch

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Figure 132 Context and environment Sketch

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Appendix 5 Perceived satisfaction of Needs

Need User need Importance Dexterity Elliptical Step Up

Number factor Builder, Trainer, Station
a_space a_space 300mm
&
450mm,
a-Space

1 To feel confident and comfortable with their 4 5 5 4

ability

2 To engage socially with other users and to feel 3 1 3 3

accepted in that group

3 To facilitate interaction particularly with 4 1 1 1

grandchildren or young relatives

4 To be safe emotionally 4 4 4 4

5 To be safe physically 5 5 2 4

6 Durable, long life span 4 3 2 5

7 Affordable for a local council, government facility 3 5 1 4

or private care facility

8 Meet relevant Australian standards for all 5 5 5 5

stakeholders

9 Socially and culturally acceptable for the target 3 5 5 5

demographic

10 Provide return through good performance reviews 2 1 3 3

and testing, high use and activity

Total 137 116 143

Price $k 0.95-1.2 5-7 1-1.5

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 Needs

their ability

To be safe physically
To be safe emotionally
to feel accepted in that group
Appendix 6 Needs-Metrics Matrix

grandchildren or young relatives

Metrics

To feel confident and comfortable with

To engage socially with other users and

To facilitate interaction particularly with

*
*
*
Ambiguous difficulty level (Y/N)

*
*
Jack Gregory: SED304 Product Development, 2018, trimester 1

Number of features that can be used by multiple people

107
Number of features that can be used or appeal to young children

*
Number of signs or related equipment to encourage a friendly atmosphere

*
Maximum fall height (metres)

Life Span (years)

Cost (AUD$)

Meets applicable standards (Y/N)

Socially acceptable (Y/N)

Number of users per month

Jack Gregory: SED304 Product Development, 2018, trimester 1

Durable, long life span *

Affordable for a local council, *

government facility or private care
facility

Meet relevant Australian standards for * *

all stakeholders

Socially and culturally acceptable for the *

target demographic

Provide return through good *

performance reviews and testing, high
use and activity

Figure 133 Needs-Metrics Matrix

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Appendix 7 Inspiration Board

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Appendix 8 Technical Documentation

Technical documentation

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