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Backpack Hanger Mockup Build: Using Matboard to Simulate Folded Sheet Metal Parts

Also, the importance of building physical mockups vs. CAD

By Rain Noe - November 9, 2018

in Industrial Design Tips

"In product design, the importance of building mockups and simple prototypes cannot be underestimated," writes industrial designer Eric Strebel. "The knowledge gained from the exercise, to touch, hold and use the object in real life, is legitimately worth the time invested."

"Seeing what you learned from a mockup gives you a leg up in the development process before you get to CAD. It also helps you avoid pitfalls that can't be as easily identified in CAD."

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To that end, in this video Strebel creates a mockup of a variant of his backpack hanger design that will ultimately be fabricated in sheet metal. To simulate the sheet metal, he uses simple matboard. Here's his process:

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Alex Netz

6 years ago

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Very well produced video, following your process is interesting. But here’s my constructive feedback:
As designed, it would be impossible to manufacture this out of bent metal. You chose to design the bottom flat into 2 split parts that fold into eachother, and also have a bend that folds into the vertical back. ( the bend you discuss at around the 11th minute mark). The thickness of the material would make this triple fold impossible unless you add clearance between all the fold. Additionally it would take a deep reach for a metal break to get into that last fold, and you didnt contend with the fact the edges converge in the middle of a scree hole. The point of mocking up is to visualize how the design can be further simplified. Why not make the whole piece from what might look like a t-shaped piece, only 3 folds required?in fact, the joint between the back face and the bottom face can be sharper fold, say 110degrees instead of 90, and that will give you already the slant for the key holding tabs.

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- Eric Strebel
  
  Alex Netz
  
  6 years ago
  
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  Hmm, sounds interesting, not sure i follow in the t shape thing. Can you include a sketch. I do realize that the what I have, will present a few issues, I sort of anticipated that it will be tricky to fold. My hope is to build it out of flat stock, but I am rather curious about what you suggest. Thanks for the feedback. look forward to your reply.
  
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  - amunta nul
    
    Eric Strebel
    
    6 years ago
    
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    Those bend radii are WAY too tight as well. Rule of thumb: interior radius = material thickness. Designing this in CAD would give you far more accurate results, with the ability to see flat pattern on demand, and then you could 3D print it to see it in person. That method doesn't make for a very interesting video, though
    
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David Duyker

6 years ago

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I love the dedication to prototyping shown here! Really great but you do start out this with contradictory statements. I think you meant to say "In product design, the importance of building mockups and simple prototypes cannot be overestimated,"

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