In the UPPS-project, Dopple, together with Delft University (IDE), has worked out the question of how to make fully personalised earbuds. We started by building a database. This database consists of a 3D scan of the ear canal and concha, a full 3D head scan, and a photo of both ears. A statistical 3D ear model was generated from the 3D ear scan data. With a master thesis, a link was made between different ear scan techniques and the modelling of the ear fit of the client by using Grasshopper software. Placing of the electronics in the ear scan data is done manually. With the course Computational Design For Digital Fabrication, various methods have been tested to modulate the ear fit and positioning of the (Dopple) electronics, with the intention to prepare for an automated process

This project, carried out in collaboration between TU Delft and Bata Industrials within the nextUPPS framework, aims to revolutionise safety shoe inlays using Industry 4.0 technologies like 3D scanning and printing. Addressing the lack of personalisation in current safety footwear, which often leads to discomfort and health issues for workers, this initiative seeks to craft inlay soles tailored to individual foot dynamics. Through comprehensive research, including literature reviews, expert consultations, and market analysis, the project identified the potential of Fused Deposition Modelling (FDM) of Thermoplastic Polyurethane (TPU) for creating these custom soles. The design process leveraged detailed foot data from 3D scans and dynamic pressure measurements, enabling the development of a 3D-printable inlay sole with a gyroid lattice structure for optimal pressure distribution and comfort. Prototypes were tested in real-world scenarios, demonstrating significant improvements over conventional inlays. This project not only highlights the importance of personalised inlay soles for worker comfort and safety but also sets a precedent for future advancements in safety footwear manufacturing.

This project aims to design a parametric, 3D-printed chair personalised to the unique body characteristics of home office workers, addressing the challenges posed by traditional office chairs in home office environments. The chair's design priorities ergonomic support, seamlessly integrating into the user's home while promoting a healthy posture. The process involves extensive research into chair design, market trends, and ergonomic principles, coupled with user interviews and literature studies to define a healthy posture. A key component is the development of an algorithm that translates body measurements into a customised chair design. This design focuses on supporting various postures, ensuring comfort, and maintaining a natural spine curve. The project's initial phase includes creating a chair prototype, conducting user tests, and refining the backrest shape through diverse measuring techniques. The chair's design particularly emphasises the backrest and lumbar support, essential for a balanced and comfortable sitting experience. Future research will concentrate on further validating the backrest, enhancing measurement methods, developing other chair components, improving comfort, and streamlining the customer experience for chair acquisition. This innovative approach to chair design not only offers a personalised seating solution but also contributes to the broader understanding of ergonomics in home office settings.

This project focuses on the design and development of an adjustable sit-wake seat for beginners with physical disabilities. The aim is to create a seat that is easy to adjust, optimized for manufacturability, and extends the lifespan of the product. The project builds upon the research and concept design of an adjustable sit-kite seat by Marinke Callens, incorporating ergonomic data and anthropometric measurements to improve fit and pressure distribution. The switch from sit-kiting to sit-waking was made to create a more controllable test environment and to target a broader market. The design process follows the double diamond method, involving phases of discovery, definition, development, and delivery, with extensive user testing and rapid prototyping to ensure functionality and usability.

The smart safety shoe is a collaborative project between Allshoes safety footwear and TU Delft, initiated in 2020. The project aims to develop a safety shoe equipped with pressure sensors and machine learning capabilities to prevent lower back pain among logistics workers. Previous efforts involved two graduation projects and a student course, resulting in a prototype capable of detecting unhealthy lifting postures. This project focused on advancing the shoe's development, evaluating two sensor layouts using high-end pressure sensing insoles, and testing these on 16 participants performing various lifting tasks. The selected layout demonstrated superior performance and was further refined for future development. The shoe, now publicly presented by Allshoes, aims to enter the market by 2025, with ongoing improvements to its machine learning model and integration of additional sensors and actuators to enhance its functionality.

This project focusses on augmenting the ergonomic comfort of breast pumping by addressing pump-related discomfort and advancing ultra-personalisation. Through an in-depth examination of lactation principles and the challenges mothers face during breast pumping, two primary pain points were identified: the absence of emotional connectivity with breast pumps, hindering milk ejection, and discomfort arising from poorly matched breast pump shields. Envisioning a solution, the project proposes a breast pump design optimised for emotional and physical stimuli, alongside an improved pressure distribution to alleviate discomfort. The design process involved the development of a perfect-fit silicone shield, employing 3D scanning for precise contour mapping and material testing for optimal comfort. The novel shield design was evaluated through pressure distribution analysis using phantom breasts, showcasing a more uniform force application compared to conventional shields. This innovative approach marks a significant stride towards ultra-personalised breast pump design, promising a more comfortable and effective pumping experience.

This project, a collaboration between Philips Experience Design and the NEXT UPPS team, is centred on the ultra-personalisation of Philips electric breast pumps. It acknowledges the diverse and unique needs of mothers, aiming to tailor the breast pumping experience to individual preferences through a user-centred design approach. The project explores the use of a product customisation webpage and a self-scanning mobile app to facilitate the collection of personal data and preferences. These tools enable mothers to actively participate in the customisation process, helping them understand and articulate their needs more effectively. User testing has shown that the Q&A interaction on the webpage can enhance user engagement by prompting reflection on product needs, while the mobile app's guidance simplifies body measurement, albeit with some data-sharing concerns. The project underscores the potential of personalisation in improving user satisfaction and highlights the importance of user involvement in the design process.

This project aimed to design a process to convert 3D scans of cyclists into durable, practical, life-size cycling mannequins in various positions for aerodynamic testing. A collaboration between Team DSM, Fieldlab UPPS (Industrial Design at TU Delft), and Aerospace Engineering at TU Delft, combined practical sports knowledge with multidisciplinary research to innovate the aerodynamic testing of mannequins in wind tunnels. Through scanning ten cyclists in different biking positions and calculating an average, a generic mannequin for time-trial cycling was created. This, alongside open-source models for 3D printing, sets a new standard for aerodynamic research. A prototype was also developed to explore practical usage techniques, resulting in a segment-based design for ease of handling and transport.

The aim of this project is to design an ergonomic kite seat tailored for beginners in kiteschools. The focus is on people with physical disabilities, such as spinal cord injuries, amputations, or spina bifida. The current high cost and lack of accessibility of specialised kite seats hinder kiteschools from offering adapted courses. By developing a single, adjustable kite seat, the project aims to reduce costs and improve ergonomics and practicality. Research included gathering anthropometric data through existing datasets, manual measurements, and 3D scans of the target group. This data highlighted the unique requirements for pressure distribution and fit. The final design reduces the need for multiple seat sizes, thus decreasing investment and storage requirements, while providing design guidelines and a prototype for testing.

The Coopi project is an innovative exploration in the realm of furniture design, specifically targeting the modern home workspace. It focuses on creating a custom-fitted chair that harmoniously blends manual craftsmanship with the precision and versatility of robotic 3D printing. This project is the culmination of research and design efforts aimed at producing a chair that not only provides comfort and ergonomic support but also serves as a stylish addition to contemporary living spaces. The design process was guided by the limitations and opportunities presented by digital manufacturing techniques, particularly 3D printing, to ensure a realistic application in a startup context. Through an extensive ideation process, the project examined various aspects including manufacturing the seat, enhancing comfort, ensuring sturdiness, and achieving a visually appealing design. The outcome, Coopi, is a chair that showcases a bold, open, and trendy character, designed to fit seamlessly into modern home workspaces while highlighting the innovative use of manufacturing processes .

This collaborative project between UPPS, Amsterdam UMC and nSize is aimed to revolutionise paediatric intensive care by developing personalised non-invasive ventilation (NIV) masks for children, leveraging 3D scanning and printing technology. In light of the detrimental side-effects associated with conventional invasive ventilation methods—such as infections and long-term lung damage—there has been a significant shift towards NIV, particularly for the over fifty per cent of children in intensive care who require ventilation due to severe respiratory distress. However, the effectiveness of NIV is highly depended upon the mask's fit, with a notable scarcity of suitably sized masks for young children. The project was spurred by Jip Spijker's graduate work, which produced design options for tailored masks that enhance ventilation efficacy. Focusing on creating a modular mask that can be custom-fitted for individual paediatric patients through 3D printing, the project aimed to improve treatment outcomes on paediatric IC units. The primary objective was to devise a process for the rapid production of ideal custom-fit masks for children aged 0-7 years, intended initially for hospital use within a 24-hour timeframe.

Made4Eyes B.V. (M4E) has been customizing eyewear since 2015 using 3D scan and 3D printing technology. M4E uses a Structure Sensor from Occipital to scan the spectacle wearer. At the beginning of 2019, M4E launched a new brand, custom-made glasses from Maat!, aimed at people who do not have a standard face shape. These are often people with a medical condition, such as Down syndrome, people with a craniofacial (skull) disorder or other conditions.

In the past few years, M4E has noticed the necessity to innovate in two areas to guarantee or improve the quality of the glasses. Some of the clients are (small) children and have a mental disability, which makes it difficult for them to sit still for 10 seconds, which is needed for a scan to be properly registered. Another problem that occurs is the ergonomic accuracy. The ends of the legs (ear tips) are often not well enough shaped for small children and people with a strongly deviating skull shape. In these cases, the frames offer too little support, causing the glasses to sag. Since the 3D-scan doesn’t reach the area behind the ear, this geometric information is missing. By researching the ergonomics of the skull in this target group and in particular the shape behind the ear, Maat! wants to obtain insight into the similarities and differences between the age groups and any common disorders. The shape of the nose and the weight of the glasses (as a result of increasing strength) will also determine the design of the spring tips.

‍

This project by The Makers, a B2B company, investigates the shift from conventional measurement techniques to a digitised system using 3D scanning to improve tailor-made suit production. Aiming to double tailor-made suit output, the initiative focuses on developing accessible scanning technology and algorithms for accurate body measurement analysis. This response to a growing demand for digitalised shopping experiences seeks to offer a more personalised approach to suit customisation. Despite obstacles, such as COVID-19 disruptions, the project offers deep insights into the operational dynamics of suit production and evolving consumer preferences.

GEOsatis, in collaboration with Fieldlab UPPS and TU Delft, worked on developing an innovative ankle bracelet for offender rehabilitation, aiming for a fit that is both secure and comfortable across a wide range of ankle sizes. Initial sizing was based on an anthropometric study of Swiss subjects, but faced challenges like accommodating large ankles and ensuring comfort at size boundaries. The project leveraged a larger 3D database of the US population, analysing diverse ankle dimensions to refine the bracelet sizing system. A sizing tool was developed and iteratively improved, incorporating factors like ankle circumference, width, and tibia tilt angle, alongside a safety margin for removal. Despite enhancements, differences in size distribution and actual order ratios necessitated additional validation studies, which adjusted the tool based on findings like the optimal fit margin. Future efforts will focus on integrating validation study results, observing the bracelet donning process, and understanding the impact of demographics on size distribution.

This project aims to revolutionise the lingerie sector by introducing an innovative digital tool designed for lingerie designers, pattern makers, and manufacturers, accelerating internal processes and embracing inclusivity of shape and size variations. Despite the traditional nature of the lingerie industry, where the creation to client delivery process can extend up to 18 months, this initiative proposes the integration of 3D prototyping to enhance design, development, and production. By replacing physical samples with digital 3D models, the project promises faster, cost-effective, and sustainable solutions, addressing the current limitations in fitting and visualising diverse breast shapes and sizes. The tool will be compatible with software like CLO3D, adjustable for realistic shapes and sizes, and capable of predicting the effects of different brassiere models. Using statistical shape modelling, the digital avatar will allow for adjustments to cater to variations in women's breast volume, shape, skin tone, and personal preferences, thereby addressing the industry's challenge of inclusivity and paving the way for mass customisation and improved online shopping experiences.

This project focuses on developing an innovative safety shoe equipped with sensors to monitor and prevent musculoskeletal disorders (MSDs), particularly low back pain (LBP), prevalent in sectors like warehousing and construction. By integrating pressure sensors within the shoe, the project aims to collect plantar pressure distribution (PPD) data, which can be analysed using machine learning to detect risky postures and provide feedback to the user. The initial phase involves extensive literature research on ergonomics and biomechanics, followed by the design and prototyping of a smart insole to validate the concept. This iterative process aims to prove the feasibility of using AI to analyse ergonomic data and develop a functional prototype that can potentially reduce work-related injuries.

The objective of this project was to engineer a wrist guard specifically designed for professional football goalkeepers, offering a robust and comfortable alternative to traditional wrist taping methods. The primary challenge addressed by the project was the prevalent issue of wrist overextension injuries among goalkeepers, necessitating a solution that would allow essential wrist movements for effective goalkeeping while preventing injurious extensions. The design process was characterised by the innovative use of parametric modelling, enabling the creation of personalised wrist guards tailored to individual goalkeepers' anatomies for enhanced protection and comfort. Furthermore, the project employed co-creation methodologies, engaging directly with professional goalkeepers and hand therapists to refine the wrist guard's design to meet the exacting demands of professional play. The resulting product is not only a testament to the project's success in blending protection with performance but also sets a new benchmark in the development of protective sports equipment, emphasizing customization, user comfort, and sustainability.

The project investigates the potential of transforming traditional safety shoes into smart safety shoes to prevent occupational incidents in the construction and logistics sectors. By incorporating smart technology, these shoes aim to provide continuous, real-time, and personalised risk assessments, addressing the shortcomings of current safety programs. The project includes an extensive literature review and practical insights from semi-structured interviews and case studies. The design concept integrates sensors and machine learning to detect leading and lagging indicators of manual handling incidents. The smart shoes then communicate these insights to employees, supervisors, and training providers, fostering a hybrid system of reactive and proactive incident prevention. This innovative approach promises to enhance workplace safety significantly by supporting and improving existing safety measures.

This project aims to innovate in the knitwear market by developing a service that enables customers to personalize, assemble, and fit their high-quality knitwear, enhancing the purchasing experience with a sense of involvement and satisfaction. Focused on circular production, the initiative seeks to reduce waste and promote sustainability by introducing an interaction design that facilitates the DIY measurement of body sizes for virtual fitting. This approach has been tested with 13 participants, leading to the creation of sweaters tailored to their preferences and measurements. The project addresses the challenge of unused inventory in the fashion industry, where 30% of clothing remains unworn, by advocating for on-demand production and fully fashioned knitting, which further reduces waste by eliminating cutting losses. The integration of new technologies such as body scanning, VR and virtual fitting into the online shopping experience allows for precise customization and fitting, potentially extending the lifespan of garments and contributing to a more sustainable fashion ecosystem.

STRIKKS' project "Personalisation in Knitwear, a contribution to a sustainable wardrobe" aims to merge the ongoing changes in the fashion industry with consumer awareness and the demand for individualisation, using the fascination for knitting and the capabilities of current knitting machines. The developed process allows customers to personalise their clothing by selecting a model, color, and knit fabric through an interactive method that visualises the garment for the customer immediately. The collaboration with TU Delft and the graduate student enhances the project by exploring various clothing visualisation methods, focusing on user experience to encourage the purchase of personalised knitwear. The project's outcomes include a detailed analysis of the current personalisation process, the use of Clo3D software for graphical representation, and the realisation of visualisations and knit garments with test subjects. The findings underscore the value of digital visualisation in personalisation but highlight the need for improvements in avatar personalisation, customer engagement with sizing, and the accuracy of fabric drape representation, suggesting that enhanced software and computing power are necessary.