Seeking an Apprenticeship, Trainee Position, or Entry-Level Role in Civil Engineering
2024 - 2026
2 Academic Years
To design and manufacture a modular shopping transport system that reduces physical strain during shopping by improving organisation, ergonomics, and the movement of groceries between the supermarket, vehicle, and home. The project followed a complete engineering design process, from client research and concept development through CAD modelling, manufacture, testing, and evaluation.
User-centred design
Ergonomic measurement
Anthropometric analysis
CAD modelling (Onshape)
Technical drawing
Design for manufacture
Prototype development
Mechanical assembly
Iterative design
Testing and evaluation
Onshape CAD
Laser cutter
Pillar drill
Mitre saw
Hand tools
Measuring equipment
Mechanical fixings
Workshop PPE
Allen keys
Mild steel tube
Key Klamp fittings
Birch plywood
Aluminium runners
Stair-climbing wheels
Mechanical fixings
Client research
Concept generation
CAD modelling
Prototype development
Material preparation
Mechanical assembly
Functional testing
Evaluation and refinement
The completed prototype successfully combined a modular shopping storage system with a lightweight transport chassis. The removable storage box transferred directly into the vehicle, while the dismantlable frame allowed the entire system to fit inside the car. Adjustable handles, stair-climbing wheels, and compartmentalised storage addressed the client's ergonomic requirements while demonstrating the successful application of user-centred engineering principles.
This project was developed using a user-centred engineering approach, where every design decision was based on solving a real problem experienced by the client. Rather than beginning with the appearance of the product, I first identified the practical challenges involved in transporting shopping safely and comfortably before developing engineering solutions to address them.
The project combined ergonomic design, anthropometric measurement, structural design, material selection, and mechanical assembly to create a functional prototype. Measurements of both the user and the operating environment were taken before any manufacturing began, ensuring the design was driven by evidence rather than assumptions.
The client experienced persistent back pain caused by degenerative disc disease, making routine shopping increasingly difficult. Conventional shopping bags required repeated lifting, often tipped over in the car boot, and placed unnecessary strain on the back when loading and unloading. Existing shopping trolleys solved some of these problems but introduced others, including poor organisation, awkward lifting, and limited compatibility with different vehicles.
Design and manufacture a modular shopping transport system capable of:
Reducing bending and lifting.
Organising shopping into separate compartments.
Sliding directly into the vehicle.
Providing adjustable ergonomics.
Remaining lightweight while maintaining structural strength.
Being practical to manufacture within the available school workshop.
The final trolley was developed through multiple stages of concept generation, client evaluation, and CAD development. Each iteration identified new challenges and informed the next stage of the design process, resulting in a solution that balanced practicality, manufacturability, and the client's requirements.
The final prototype was the result of a continuous design process rather than a single finished idea. Each stage built upon the previous one through research, client feedback, engineering analysis, CAD modelling, and practical manufacture. As the project progressed, several aspects of the design were refined in response to structural analysis, manufacturing limitations, and testing. One significant redesign followed the CAD development stage, where weaknesses in the original chassis highlighted the need for a more stable and manufacturable solution. Rather than treating these changes as setbacks, they became an important part of the engineering process, resulting in a stronger, more practical product that better met the original design objectives.
Every design decision was made with the client's needs in mind, rather than producing a generic product. Measurements of the client's height, vehicle dimensions, and shopping requirements were collected before establishing the final design parameters.
Handle height was determined using the client's measurements to improve comfort and reduce unnecessary bending. Adjustable handles allowed the trolley to be fine-tuned to the user.
The original concepts exceeded the manufacturing capability of the available workshop equipment. Rather than abandoning the project, the design was simplified and re-engineered using readily available materials and mechanical clamp fittings while maintaining the original functional objectives.
Separating the storage box from the chassis allowed shopping to be transferred directly into the vehicle without lifting the entire trolley. The dismantlable chassis also enabled the product to fit inside the car when not in use.
The design evolved continuously throughout the project in response to client feedback, manufacturing limitations, testing, and practical experience. Each iteration improved the functionality and manufacturability of the final prototype.
One of the biggest challenges was translating ambitious design ideas into a product that could realistically be manufactured using the equipment available within a school workshop. Several early concepts introduced complex mechanisms that proved impractical to build, requiring the design to be simplified without compromising its purpose.
The original chassis design incorporated features that exceeded the capabilities of the available tools and manufacturing processes. Alternative construction methods and modular mechanical joints were introduced to achieve similar functionality using accessible materials and equipment.
The project remained flexible throughout manufacture. Practical improvements, including the introduction of stair-climbing wheels, increased adjustability, and additional structural support, were incorporated as the prototype developed, demonstrating the importance of continual evaluation throughout an engineering project.
✓ Client measurements verified before design development.
✓ Vehicle dimensions confirmed before determining product size.
✓ CAD dimensions checked before manufacture.
✓ Components measured before cutting and assembly.
✓ Mechanical fixings checked for alignment and security.
✓ Prototype tested for stability during movement.
✓ Storage box checked for smooth removal and installation.
✓ Handle adjustment tested for comfort.
✓ Stair-climbing wheels evaluated during practical use.
✓ Chassis inspected for rigidity and structural stability
✓ Wheel alignment checked to ensure smooth manoeuvrability
✓ Prototype tested against the original design specification
✓ All mechanical fixings tightened and rechecked after assembly
✓ Storage compartments checked for consistent dimensions and fit
✓ Prototype tested under a representative shopping load
✓ Overall dimensions verified against vehicle boot measurements
✓ Product inspected for sharp edges and user safety
This project fundamentally changed the way I approach engineering design. I learned that successful engineering is rarely about producing the most complex solution. Instead, it requires understanding the problem thoroughly, working within realistic constraints, and continually refining ideas as new information becomes available.
I also gained a much greater appreciation for the importance of planning before manufacture. Taking accurate measurements, understanding the user's requirements, and considering manufacturing limitations at an early stage significantly reduced problems later in the project.
Perhaps most importantly, I learned that design is an iterative process. Some of my favourite ideas never reached the final prototype, but each one contributed to a better overall solution.
User-centred design
CAD modelling
Technical drawing
Ergonomic design
Anthropometric measurement
Mechanical assembly
Prototype manufacture
Functional testing
Iterative design
Engineering evaluation
Problem-solving
Critical thinking
Attention to detail
Adaptability
Planning and organisation
Resilience
Quality focus
Communication with a client
Responding to feedback
Continuous improvement
This was my first opportunity to experience the complete engineering design process from initial client consultation through to the manufacture of a working prototype. Looking back, the final product is very different from my earliest concepts, but I now see that as one of the project's greatest strengths rather than a weakness.
Every design change was driven by evidence, whether through client feedback, testing, measurements, or manufacturing limitations. Learning to adapt my ideas without losing sight of the original objective taught me that engineering is a process of continual improvement rather than pursuing a perfect first solution.
The project strengthened my confidence in CAD, manufacturing, problem-solving, and iterative design while reinforcing the importance of designing around the user rather than the designer. It remains one of the projects I am most proud of because it solved a genuine problem, challenged me to think like an engineer, and demonstrated how thoughtful design can have a meaningful impact on someone's everyday life.