Mechanical Engineering Portfolio | Redesigning Ergonomics

Reverse Engineering an Umbrella Handle

I had to model an object with complex shapes for a class project. What came to mind was an umbrella that was uncomfortable to hold. I went beyond the expectations of simply modeling the handle by making the CAD model easy to modify for redesigning a more ergonomic handle.

Computer Aided Design Course, Spring 2018

Goal

Make a CAD model of an existing umbrella handle to design a new ergonomic handle

Results

A CAD model of an umbrella handle with a more ergonomic grip that can easily be redesigned

Modeling the Original Handle

I used the Surface Sweep feature on SolidWorks to capture the shapes of the handle. This approach makes redesigning easier because I could make big changes to the shape by simply changing the guide curve.

The guide curve of the original handle was captured by a contour gauge, shown on the left.

The length of the path was measured with a caliper.

The profile of the bottom face of the handle was traced onto paper.

Finger and palm grips modeled using surface sweeps

Comparison of the CAD model and the original handle

Redesigning for an Ergonomic Grip

I redesigned the handle to fit my personal hand by using modeling clay to capture the shape of my hand when I grip a cylindrical object. Following the same method as modeling the original handle, I measured the shape of clay using a contour gauge.

Results and Design Improvements

Modeling the complex shapes was simplified by using advanced SolidWorks features, which allowed for easier modification of the model and design. At the same time, I discovered a fun and quick way to make a handle with a custom fit grip. Adjusting the shape of the guide curve can be done to create a more universal and ergonomic handle.