ROTOPOD: VR CHAIR

Skills: Market Research, Competitive Analysis, FEA Analysis, Rapid Prototyping, Assembly,

DFMA, FMEA, DFE, User-Testing and Feedback

Machines: CNC, Drill, Laser-Cutting

Software: SolidWorks, ANSYS

For my senior capstone project, my team's goal was to provide a cost-effective VR chair. VR is a growing field beginning to tap into its own potential, and with a lower price point, our target market includes normal users who want to save and experience a higher-end chair that responds to their movement.

My team consisted of 5 people. Our design is the RotoPod, a chair which outclasses our competitors by being more comfortable, economical, ergonomic, and versatile. This versatility is a key feature of the chair - it can be used as an eye-catching and unique lounge chair, safer alternative to a rocking chair, or, in the application we’ve deemed most viable: a responsive and budget friendly VR chair.

Prototype 1

Product Study: Office Chair
Competitive Analysis: Pugh Matrix
Market Research: User and Expert Interviews, Product Reviews, Focus Group
Design Conceptualization: 100 Ideas
Proof of Concept

For Prototype 1, we wanted to explore a chair using magnetic levitation for comfort. However, after testing and simple calculations, the power required was too high and would not provide a cost-effective solution. This motivated us to change direction in our design for prototype 2.

Prototype 2

House of Quality
Design Analysis
Mechanical Analysis: Failure Modes, Natural Frequencies, Damping
DFMA, FMEA, DFE
Assembly

Based on mechanical analyses and expert interviews, we decided to use a bed of conical springs to provide comfort and maneuverability. We designed a double triangle arrangement for the springs, varying in horizontal or 45 degree-angled orientation for force and torsional stiffness in side-to-side motion. The chair was made by CNCing 1/2" plywood and forming it in a grid. With this design, the chair can support up to 396 lbs.

Prototype 3

Mechanical Analysis
Design Documentation: BOM, CAD Drawings
Cost of Manufacturing
Final Assembly and Design

We incorporated rubber disks and sleeves for damping the springs in our final prototype. In terms of the final design, the RotoPod is durable and built with high strength materials, such as fiberglass. It is also fairly cheap and easy to manufacture - the process we chose use for the main chair component is compression molding since our production volume is estimated to be 3,000. Other parts such as damping rubber and the base will use die-cutting and 3D printing. The total manufacturing cost for one chair is $4.51, so with manufacturing and environmental considerations, our total chair cost is $399.71, which is $1,100 (73%) cheaper than the Roto VR chair currently on the market.