Travel Safe
ERGONOMICS | SHEET METAL FORMING | TIG WELDING
As an avid traveler, I decided to make a product I've always wanted: a lightweight, secure container to keep my traveling tools (cameras, passports, money, etc.) safe.
The ergonomic curves of the design allow comfortable use as an insert for a large travel backpack, and aluminum alloy body not only provides structural safety for any fragile objects, but is also strong enough to deter most theft when locked to an exposed rod or beam (i.e. bed posts, exposed pipes, etc.) using a carbon steel bike lock. The aluminum construction and "mini" u-lock weigh a total of 6.5 lbs, maximizing portability.
The geometry allows storage of a DSLR with two lenses and a small tablet computer, in addition to essentials like a passport, cell phone, hard drive, and other small electronics. The container welds are watertight, and the lid closure uses a press fit to provide a thorough water resistance. In addition, the interior is lined with protective padding that prevents damage to electronics from internal motion.
Inspiration
Whether I was travelling for work or pleasure, I hated keeping track of my stuff. As much as I tried to travel "light", I found that there were a few things that I couldn't do without: a camera to help me remember the trips, a computer to help me stay in touch with friends and family at home, and a passport to get home. Add on travel comforts like music, copies of credit cards, a journal, and pretty quickly there was a big bag of stuff that I needed to, but wasn't happy about keeping safe and sound.
Because of that, I was nervous giving my bag to people who couldn't have cared less if it got smashed, wet or lost. Even if you manage to get it safely between destinations, it's all too common to have things go missing from "secure" rooms. The only alternative is to take these things with you everywhere you go, which is not only inconvenient, but often times impossible, especially if you are going some place your things can't follow, (near, or under water) or some place you don't want them to follow (out to a social or business meeting).
Because of that, I was nervous giving my bag to people who couldn't have cared less if it got smashed, wet or lost. Even if you manage to get it safely between destinations, it's all too common to have things go missing from "secure" rooms. The only alternative is to take these things with you everywhere you go, which is not only inconvenient, but often times impossible, especially if you are going some place your things can't follow, (near, or under water) or some place you don't want them to follow (out to a social or business meeting).
Design
The design process began as a series of sketches. Originally the geometry was a regularly rectangular, which is just a euphemism for a box. However, after rapid prototyping that design with some cardboard, I realized how uncomfortable and "clunky" that design would be. Ergonomic curves would make it more comfortable during use, as well as establish a unique form factor for the product. I then used solid modeling and more cardboard prototypes to determine the appropriate size of those curves, further refining my design. I began considering the closure and locking mechanisms, and after considering dozens of alternatives, realized that no existing solutions integrated the two. To me, this seemed like the best way to minimize parts while maximizing the reliability of the safe, so I designed the lid and body to be "locked" to one another via the bike lock, which would also secure the safe to the environment. From here the design process became a function of problem solving the fabrication and assembly of the final product.
Fabrication
The material best able to produce structural stability while maintaining a light weight was an aluminum alloy, and to effectively work and weld the metal I selected 5051 sheet metal. The process for creating the organic curves was largely iterative, and taught me a great deal about working sheet metal. Further complicating the process was my goal of mastering aluminum arc welding. As you can see form the photos, my first attempts were quite poor. However, after many, many hours practicing, I was able to achieve fully penetrating welds that were waterproof and structurally sound enough for me to grind them completely down without compromising their integrity. To accurately machine the lid and closure involved more band sawing, milling, and belt sanding then I would like to admit. Even after the initial structure was completed, I spent plenty of time hand sanding, and finally sand blasting the outside to achieve the desired surface finish, and cutting and placing the inner padding to achieve the supportive inside.