Jesse Brown
Travel Tough
A modular, protective case for powered wheelchair joysticks during air travel
Skills
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Woodworking
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Milling
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Sketching
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Branding
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Brainstorming
Course Project
Problem
When people who use powered wheelchairs fly on planes, they must check their wheelchairs as luggage. During the stowing process, the wheelchairs are often mishandled leaving key components damaged, namely the joystick.
Requirements
The solution should...
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Protect against damage during all phases of the loading process
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Not be so large that it can not fit into a suitcase
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Be modular
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User would like to store this when not travelling
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be easy to attach and detach
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User has limited mobility
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Approach
Research and User Interviews gave us insight on the main causes of damage to the joysticks
1) Exposure to Elements
Wheelchairs can be left outside of the plane for extensive amounts of time no matter the weather conditions
2) Unwanted Tampering
Loading crews often try to use the joystick to move the wheelchair for them which can cause damage
3) Difficulty Loading and Storing
Loading crews grab anything they can to load the wheelchair onto the plane breaking vulerable components
We then began brainstorming and prototyping. After considering the requirements for each option, we started constructing the 3 main components for the product.
The screw-on metal plate attaches securely to all wheelchairs with a railing system. This allows for a sturdy, non-altering way to attach the Travel Tough. This component was custom milled from a plate of aluminum to be both light weight and strong.
The protective case features Grade A quarter inch plywood as a hard shell, a hugging foam interior, easy to use latches for attachment and secure closure, and a water proof outer wrap. The case attaches to the plate with the latches on both sides.
We created a water proofed sleeve for the arm rest to protect the exposed wires from weather and snagging on other luggage. The sleeve attaches with a large Velcro band.
The final part to this project was branding our product. The goal was to create a simple logo that anyone can understand the general context and application for the product.
Solution
Combining all components yields a product that meets all 4 requirements. The Travel Tough allows users to avoid the almost inevitable damage to their powered wheelchairs. I learned how to integrate custom parts with existing parts by machining metal on the milling machine as well as precise woodworking for structural integrity.
