KEY BENEFITS:
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Transformable from Cabin size to Check-in size and vice versa - under a minute
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70% hard-case for durability in frequent use
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Easily accessible compartments
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Minimalistic sleek design that blends with professional outlook
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Can be stored in minimal volume configuration when not being used
TRANSFORMABLE SUITCASE DESIGN
CONTEXT
Most products are usually not well designed as evidenced by the seemingly poor quality of common consumer products. As a cornerstone project in course 2.739 (Product Design and Development), I teamed with a diverse group of students from MBA, Mechanical Engineering and Industrial Design to design a user-centered travel suitcase that meets diverse travel needs of frequent urban business travelers.
AIM
Create a user-centered suitcase design that empowers frequent urban business travelers with diverse luggage volume needs and crunch in storage space, and are currently limited by functionality of a traditional suitcase.
RESULTS
We worked over five 2-week sprint cycles to create Morphus, a minimalistic, sleek and robust transformable suitcase that can transform into either cabin luggage or check-in luggage to meet the specific need of a urban business traveler who is crunched for space of owning two separate traditional suitcases. Our customers loved the prototype of the product and wanted to own a production version.
CONTRIBUTIONS
Voice of Customer Interactions
User Needs Analysis
Design Specifications
Concept Generation
CAD Models
Prototype Design
User Testing
I conducted user interviews, identified needs, generated design specifications, brainstormed concepts, created low fidelity prototypes and designed the hinge mechanism that is central to our product. I also conducted ergonomic tests with users with the "feels-like" prototype of our design.
COLLABORATIONS
Alice Wang, Industrial Design
AJ Huang, MBA
Assaf Yablon, MBA
Don Coates, Global Operations
Hugo Huang, MBA
Rishab Mardia, Mechanical Engineering
Yunpeng Liu, Mechanical Engineering
DESIGN APPROACH
Voice of customers
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“I prefer large hardcase suitcase because it is durable”
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“ My priorities are sturdiness and packable volume.”
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“Good quality wheels and handle are very important.”
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“I just don’t want to look at luggage at home, I want to hide it away. It is not pleasing.”
Mr. X, Freelancer
25+ Trips annually
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“I worry that softer fabric based suitcases are less durable”
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“It will be nice to have suitcase that can be repurposed to different sizes for road trips and air travel.”
Ms. Y, Graphic Designer
2 Trips annually
Carry-on size Check-in size Telescoping mechanism
Voice of Customers
To understand what luggage features frequent travelers need and value, and what their pain points were, we took two approaches:
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My teammates searched over 530 user generated reviews of competitors' products on Amazon
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I conducted in-person user interviews with travelers from diverse backgrounds, age, lifestyles and demographies.
Based on the relative importance, we identified the key needs as follows:
● The suitcase is easy to re-configure to a desired size.
● The suitcase offers various options of volumes and occupies minimum space when not in use.
● The suitcase is lightweight.
● The suitcase is sturdy.
● The suitcase is easy to maneuver.
● The suitcase is pleasing to the eyes.
Our Key Innovation
A single, sturdy piece of luggage that can be easily reconfigured to different sizes or shapes based on a specific trip's purpose.
Concept Generation
We brainstormed individually and then collectively as a team to gather various ideas that addressed the critical needs. From this exercise, we categorized similar concepts and improved upon them.
Low fidelity prototypes
We built low fidelity models and prototypes for an initial assessment of the product’s structural and functional capability. Our main concepts were:
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Concept 1: Hard-case collapsible suitcase
This suitcase can be transformed into three sizes: flat for storage, carry-on size and checked-in size. This design has advantages such as satisfying user's latent desire to store the suitcase in a flat configuration and low manufacturing cost. However, this model was not selected due to complexity of reconfiguration during use, lack of rigidity and lack of durability.
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Concept 2: Rotation expandable hard-case suitcase
This concept relies on a nested case attached with a hinge joint on one side of the hard-case suitcase to expand into a larger check-in size when needed.
This design has an intuitive and fast transformation interface and also is durable. However, we also identified challenges such as abnormal dimensions and additional weight.
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Concept 3: Telescoping hard-case suitcase
This concept relies on a nested case which can be pulled out like a drawer into a larger check-in size when needed. This design also has an intuitive and fast transformation interface and also is durable. However, we also identified challenges such as durability of the telescoping mechanism, addition of locks for providing rigidity in expanded configuration.
Concept Selection
We evaluated the three concepts based on the product specifications, user needs, and how well the concept met the needs. Based on the overall score, we selected Concept 2, Rotation expandable hard-case suitcase as out primary design concept.
Detailed Design
To design the hinge, I evaluated various hinge designs based on their load bearing capacity, angle of operation, common materials and mechanism of attachment to the hardcase shell. I chose extended barrel hinge with 180° angle of rotation and created CAD models to evaluate the assembly and appearance. I performed stress analysis calculations to determine the minimum size of the hinge.
Other features such as easy access lid, locks, hybrid frame made out of Recylex and polycarbonate, ergonomic handle, etc. have been designed by my team members.
Ergonomic testing with "feels like" prototype
Due to the closure of manufacturing facilities during COVID-19, I could not build the alpha prototype as our team initially planned. However, I built a low fidelty "feels-like" model out of cardboard, PVC pipe and foldable hand truck. Given the unusual dimensions of this design, we wanted to test how the user would perform common actions of lifting and walking with the suitcase.
Final Result
Using the product design methodology, we systematically designed a user-centric suitcase that satisfied diverse travel needs of frequent urban travelers. I assumed a leadership role throughout the project and contributed my mechanical design skills to finish the design cycle from ideation to alpha prototype.
Rotation Mechanism
