UNIVERSITY MALAYSIA SARAWAK

FACULTY OF ENGINEERING

DEPARTMENT OF MECHANICAL AND MANUFACTURING

ENGINEERING

KNP 3483 ENGINEERING DESIGN 1

GROUP PROJECT

TITLE: GREEN VEHICLE

GROUP 8 (LION REVENANTS)
NAME MATRIC NO
Darren Ling Jie Nguong 60607
Ng Boon Kiet 61728
Thian Ann Shen 62798
Nur Eizzatie Akmal Binti Md Ezam 63592
Nurul Amira Binti Othman 62211

Lecturer : Dr Abang Mohammad Nizam Abang Kamaruddin

Madam Ervina Junaidi
Academic session : Semester 1 - 2019/2020
ACKNOWLEDGEMENT
We would like to express our special thanks of gratitude to the course instructor Dr Abang
Mohammad Nizam Abang Kamaruddin and Madam Ervina Junaidi as well as the experienced
technicians in Department of Mechanical and Manufacturing Engineering who gave us a lot of
useful information and guidance that lead us to succeed the project requirement by the subject
Engineering Design 1 (KNP 3483).

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Chart 1: Gantt Chart

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1.0 INTRODUCTION ................................................................................................................. 5
2.0 CONCEPTUAL DESIGN ..................................................................................................... 8
2.1 Defining Problem ........................................................................................................................ 8
2.2 Information Gathering ............................................................................................................... 9
2.2.1 External Information ............................................................................................................ 9
2.2.2 Internal Information ........................................................................................................... 12
2.3 Concept Generation .................................................................................................................. 15
2.3.1 Axiomatic design ................................................................................................................. 15
2.3.2 Functional Requirement of the Design .............................................................................. 18
2.3.3 Design Parameters of the design ........................................................................................ 18
2.3.4 TRIZ problems solving method .......................................................................................... 22
2.3.5 Computational Fluid Dynamics ......................................................................................... 23
2.4 Evaluation of Concept .............................................................................................................. 24
3.0 EMBODIMENT DESIGN ................................................................................................... 26
3.1 Product Architecture ................................................................................................................ 27
3.2 Configuration Design ................................................................................................................ 29
3.2.1 Configurate Product............................................................................................................ 29
3.2.2 Configurate Parts ................................................................................................................ 30
3.2.3 Analysis and Refining ......................................................................................................... 31
3.3 Parametric Design ..................................................................................................................... 32
3.3.1 Analysis of Forces ............................................................................................................... 32
3.3.2 Analysis of Linear Motion .................................................................................................. 36
3.3.3 Analysis of Stress ................................................................................................................ 37
4.0 DETAIL DESIGN ............................................................................................................... 38
4.1 Final design and Dimensions.................................................................................................... 38
4.2 Bill of Material .................................................................................................................... 42
4.3 Final Product Design Specification ......................................................................................... 44
5.0 CONCLUSION ................................................................................................................... 47
6.0 REFERENCE ..................................................................................................................... 49
7.0 APPENDICES..................................................................................................................... 50
8.0 DECLARATION................................................................................................................. 59

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 1.0 INTRODUCTION
The Lion Revenant is a design team in an automobile company. Lion Revenant is needed
to design and fabricate a ‘Green Vehicle’. According to the requirement given, the dimension
for the ‘Green Vehicle’ must not exceed 0.3m length, 0.3m depth and 0.3m height. The design
that Lion Revenant can carry maximum of 5 concrete bricks with 225mm × 112.5mm × 75mm
dimensions. The model was made mostly by recyclable materials, such as the body of the car
were made from scrap plywood from workshop and the wheel was made from CDs. Lion
Revenant also use 3D printing as one of the processes to manufacture the truck. The parts that
were made from 3D printing were the accessories such as Lion Revenant’s logo, the truck head
and shaft cap.

Lion Revenant’s ‘Green Vehicle’ will be produced through the various engineering
design process. The engineering process for this project takes the whole 14 weeks, from 9th
September of 2019 to 16th December 2019. For the first week of the process, the problem was
defined, the problem definition was stated in this report under the conceptual design part. The
problem definition is important to make sure the project process was done smoothly. In any
design project, the first thing to do is to define the problems also known as problem definition.
Problem definition determines what the needs that a product must meet are, and this is the
beginning of the product development. There was a saying said, ‘understanding any problem
thoroughly is crucial to reaching an outstanding solution’. Next, after the problem definition,
the information was gathered. The purpose of information gathering is to support the planning
of the organization’s work to become more fully inclusive. Then, the gathered information is
to know the customer’s requirement and try to meet them. This is to ensure that what was
designed fulfil the requirement of the customers. There are few ways to gather information and
the most common one is through surveying the customers. First the designer must know who
their focus group is, customer complaints and warranty data. The third step in conceptual
design process is the concept generation. Concept generation answers the question of how the
product will satisfy the customer needs as mapped into the functional specifications. The
concept generation for this project was started in the second week. The concept generation
needs to make early because it will reduce the likelihood of costly problems later in the
development process. There are 5 steps in concept generation which clarify the problem, search
externally for existing solutions, and search internally, using individual and group resources.
Next, explore systematically, using concept fragments and lastly, reflect and evaluate (Wood,
2009). There were 2 different design concepts in this project that were introduced to fulfil the

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purpose. Lastly under conceptual design is the evaluation concept. Concept evaluation is the
process of grading and evaluating concepts for determination of their relative merits.

After the conceptual design, it will proceed to the embodiment design. Embodiment
design is one of the main stages of the engineering design process and can be divided into three
parts which are product architecture, configuration design and parametric design (Griffins,
2017). Firstly, the product architecture is the arrangement of the physical elements of a product
to carry out its required functions. Product architecture can fall into two categories which are
integral and modular. Next, configuration design, configuration design is the second step in
embodiment design. The importance of configuration design is to prevent any mistakes in the
product during the process. Lastly in embodiment design is the parametric design, the main
purpose of parametric design is to distribute to design variable to produce the best possible
product.

Figure 1: Design Process.

From this, the designers have achieved the four C’s of design which is, creativity,
complexity, choice and compromise. In this report, there were Functional Requirements (FRs),
two different conceptual solutions to the problem with the design parameters (DPs), it also
provided the QFD analysis, House of Quality (HOQ). For this project Lion Revenant also meet

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all the requirements needed such as recycle materials as the vehicle body, CD as wheels, using
rubber band to generate power, and 3D printed components.

Chart 2: Organization chart of the team.

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2.0 CONCEPTUAL DESIGN
Conceptual design is the first step of the engineering design process for the entire
project. There are several steps with the following sequence that been used to generate the most
satisfying design for Lion Revenants which including decomposition of defining problem,
gathering information and gathering concepts which are decomposition of concepts and
axiomatic design of the model.

2.1 Defining Problem

The first step before designing the ‘Green Vehicle’ model is to figure out all the
problems and requirement given for the design. In this project, the dimension of the model
should not more than 0.3 m (length) x 0.3 m (depth) x 0.3 m (height). Next, with the limitation
of the dimension, the end of product could not be designed oversized and at the same time it
can either travel the greatest horizontal distance with minimum 4-meter-long or achieve the
fastest speed. In addition, Lion Revenants is required to carry 5 bricks which are approximately
10,000 grams in total. Therefore, the tension of the materials used to make the model are
important to ensure that the tension of the materials used can support the mass of the bricks or
otherwise it will be counted as a failure. Next, the materials used to make the green vehicle
model must from the recycle materials as the vehicle body and the design should have 4
components with 3D printed from PLA (poly-lactic acid polymer) material.

Furthermore, the wheels of the vehicle are required to use CD. CD is a thin material
that can be broken down at any time when the load been put on it. Hence, the dimension and
the weight of materials used are the major factor to make sure the model will be moving, travel
in a straight line and does not fail. Then, the vehicle model is disallowed to have any electrical
components such as micro-controller, explosive, chemical propellants and remote control. To
generate the power for the green vehicle, the only mechanism that can be used is rubber bands.
The team is required to think about the mechanism or ways for the model to carry the load and
make it move in the most efficient way. Lastly, the drawing of the model is required to use
AutoCAD software to show the design configuration. The drawing are then export into Solid
Work for simulation purpose.

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2.2 Information Gathering

An information gathering had to be done in priority to construct a fully functioning

green vehicle. It is a crucial process in preparation for any engineering project (J, 1997). It is a
time-consuming and laborious phase, but it is the major determinant of success or failure of the
project. Generally, the related information can be gathered externally and internally. For
external information, existing sources such as survey from customer, benchmarking from the
competitors and research from reference books, journals, internet and article whereas for
internal information, the information is gathered through accessing individual or group
resources and brainstorming.

2.2.1 External Information

A. Survey
A survey has been conducted to 105 respondents for this project to gather some
information about the knowledge and the idea from random people about the green vehicle
that can carry a certain amount of load. From the survey, the most important factor that
needs to be considered is an eco-friendly product. Next, the mechanism to move the car is
the second highest followed by external design of the vehicle and the price that only
slightly different. Other than that, the rubber band is the highest with 48.6% respondents
vote for the selection to move the loads by the source of power that most environmentally
friendly. All the information from the respondents is the customer’s requirement that needs
to be considered to design the product.

B. Benchmarking
For this project, benchmarking from other company also been conduct. The purpose of
benchmarking from the competitors is to determine the functions that have the greatest
potential for improvement. The companies that related to this project are Dump Truck that
made in USA, Clockwork Elastic Car that made in China and Huina Dump Truck from
USA. From the comparison of these three company, the features product from this project
will differentiate the features and functions from other company.

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 Table 1: Comparison of the benchmark company.

DUMP TRUCK
CLOCKWORK HUINA SUMP
ELASTIC CAR TRUCK
Source Made in USA Made in China Made in USA
Materials 100% recycled Recycled paper box Not from recycled
plastic materials
Power Generation Human Rubber band Electric motor
Max load can carry 3 Cannot carry load 5
(kg)
Speciality Smaller in size Light in weight Inseparable body
and base

C. Research
The automobile was first invented and perfected in Germany and France in the late
1800s, though Americans quickly came to dominate the automotive industry in the first
half of the twentieth century (Automobile History, 2018). Henry Ford innovated mass-
production techniques that became standard, and Ford, General Motors and Chrysler
emerged as the “Big Three” auto companies by the 1920s. Manufacturers funnelled their
resources to the military during World War II, and afterwards automobile production in
Europe and Japan soared to meet growing demand. Once vital to the expansion of
American urban centres, the industry had become a shared global enterprise with the rise
of Japan as the leading automaker by 1980.

The main components of a vehicle are the battery, axle, brakes, radiator, AC compressor,
muffler, transmission, shock absorbers etc. However, in this project, Lion Revenant was
asked to build a green vehicle where the dimensions were limited to

0.3m×0.3m×0.3m

which was too small to fit in all main components of a functioning vehicle. Besides that,
the only power source for the movement mechanism is rubber bands, and recycled
materials are used to build the green vehicle. Hence, the benchmarking process for the
specification of toy cars is more suitable for this project requirement. Among the toy cars,
elastic toy car or rubber band powered car is the best choice to benchmark.

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 Basically, a rubber band car consists of the car body, wheels, axles and rubber bands.
Nowadays, the best material to make a frame is aluminium, fibreglass or wood composite.
However, they were advised to use recyclable material that can withstand the whole
vehicle body and 5 bricks which will be put inside the vehicle. Therefore, Lion Revenant
had decided to use recycled plywood as the bottom frame of the vehicle. It is because
recycled plywood is durable and easily manufactured.

Next, the gathered information is about the movement mechanism. In this project,
electricity or any kind of fuel is strictly prohibited to move the vehicle. To ensure that the
vehicle will move for longer distance, 15 pieces of CDs were used for each wheel. It is
because adding more mass will generate more inertia, which is the tendency for an object
to keep going in its current trajectory. To make the movement mechanism works, chained
rubber bands are used as requested. The rubber band is elasticity which it is returned to the
original shape after the loads causing a deformation are removed. The elasticity of the
rubber band is caused by stretching the rubber band under an applied force. The important
parameters to determine the elasticity of a material are its elastic modulus and elastic limit.
Rubber band have a low elastic modulus are easily deformed under a load.

According to Samuel J. Ling (2019), the material no longer comes back to its original
shape and size but relaxes to a different shape and size. This scenario happened when the
stress under a load becomes too high. The elastic potential energy stored inside the rubber
bands will move the wheels through the shaft. Maximum usage of chained rubber bands is
required to ensure the vehicle to reach certain velocity and distance. The precaution steps
are kept in mind that the rubber bands do not entangle during the winding process so that
it will increase the number of revolutions of the wheels and the rubber band should be
changed repeatedly to ensure there are in the original shape to generate more power.

Apart from that, the vehicle body to hold the bricks were considered. However, it is
rare to see an elastic toy car to move with loading in the market and hence, brainstorming
was needed for a loading space for the bricks. Initially, Lion Revenant planned to use 4
pieces of plywood brick as the container for bricks, but the idea was quickly rejected as it
will increase the overall mass of the vehicle. Hence, Lion Revenant decided to use 3D
printing for the frontal area of the vehicle to reduce the vehicle mass and making the
vehicle more aerodynamic. The aerodynamic design of frontal part of vehicle will
minimize air resistance and maximize the speed of the vehicle.

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2.2.2 Internal Information
Internal information is gathered through accessing individual or group resources and
brainstorming. For this project, the team members brainstorming the idea for the individual
part and all the ideas were combined through a meeting of the group. The information and idea
that been generate individually were included the information about the material selection that
only been considered from recycle material, the movement mechanism which is the
requirement for this project only by using the rubber band and the source of power. Hence, the
different ideas from the teams make the results having two different concepts of design to be
considered.

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2.2.3 House of Quality

Figure 2: House of Quality.

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 The diagram above shows the House of Quality (HOQ) that shows the relationship
between the engineering characteristics of this product, green vehicle. First, the maximum
speed of the vehicle is strongly related to the maximum distance travelled and related positively
with the power generated by the rubber bands. As the power generated by rubber bands
increases, the thrust force of vehicle which allows forward movement would become greater.
However, it is related negatively with the weight of the vehicle because as the overall weight
of the vehicle increases, the friction between the wheel and the ground increases as well.
Besides that, the maximum distance travelled is related positively with the weight of the vehicle
and the power generated by the rubber bands. As the weight of the vehicle increases, the inertial
force of the vehicle will increase which make the vehicle difficult to stop immediately. Thus,
the vehicle can move further. The overall weight is related negatively to the loading capacity.
It is because the designated vehicle weight should be as light as possible to maximize vehicle
speed. However, if loading capacity increase, it would indicate that the vehicle can hold more
loading which brings more weight to the vehicle. Although the increase in loading capacity
would affect the maximum speed which can be achieved, yet it provides additional stability to
the vehicle so that all wheels of the vehicle will have traction force with the ground. The safety
of the vehicle is no longer a concern as it is stable when moving. Furthermore, the weather-
resistant of the vehicle should be highlighted as it is positively related to safety and stability.

From the relationship between customer requirement and the engineering

characteristics, the characteristics which need to be prior are the maximum speed and
maximum distance travelled. It is because of these two characteristics correlation with most of
the customer requirements strongly. Besides that, the weather-resistant of the vehicle is ranked
at third as a good vehicle should be able to overcome any road condition and weather without
sacrifice its performance. The engineering characteristic ranked at fourth place is vehicle safety.
A product should be minimizing its risk to harm the consumers, society, and environment
before it is mass-produced. The green vehicle should be considered as safe to use because it
does not apply conventional power system such as fuel engine system which did not utilize the
fuel efficiently. However, a good green vehicle should be able to apply renewable power
sources such as solar power, hydropower, or even elastic power.

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2.3 Concept Generation

After gathering information, Lion Revenants proceed to the concept generation stage.
Concept generation stage is the critical stage as it can ensure the development process is in the
direction toward satisfying the customers’ needs as mapped into the functional specifications
(Nobel, n.d.). Which means we will have a better product with better performance since we
have look through lots of alternatives before the product is being produced. An early concept
generation will reduce the likelihood of costly problems later in the development process.
Concept generation is a 5 steps process and have look through this process in order to produce
a Green Vehicle that can travel 4 m with the carriage of 5 bricks.

2.3.1 Axiomatic design

To decide whether the car design concept is applicable or not, the axiomatic design
method was used to analyses the suitable concept design of the car. Axiomatic design is a
technique used for choosing the best concept for development into products. It involves matrix
methods to effectively analyse the transformation of customer needs into functional
requirements, design parameters, and process variables. Besides, the axiomatic design also
mainly focusses on four main concepts which are domains, hierarchies, zigzagging and design
axioms (Najib, 2004). There are two variables in axiomatic design that cannot be derived from
other laws of nature or physical principles, which called axioms. Axioms play a role to
determine the relationship between the functional requirements and design parameters, in order
to find the most suitable concept design. The two axioms are:

Axiom 1 The Independence Axiom. It maintains the independence of the

functional requirements (FRs).
Axiom 2 The Information Axiom. It minimizes the information content of
the design (DPs.

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 Figure 3: Axiomatic design.

Functional requirement (FRs) of design is set of independent requirements that

completely characterize the functional needs of the design solution in the functional domain.
While design parameter (DPs) are the key to physical variables in the physical domain that
characterizes the design that satisfies the specified functional requirements (FRs) (Mital, 2014).
To generate the best design concept, the functional requirement should correspond to the design
parameter without interrupt with other design parameters. This means the design achieves the
minimum information content and maintains the independence of the functional requirements
at the same time. In axiomatic design, there are three types of design matrices generated
through axiomatic design which are uncoupled design, decoupled design and coupled design.
The most desired of the axiomatic design matric are followed by uncoupled design, decoupled
design and coupled design. A good design must be either uncoupled or decoupled design. On
the other hand, the coupled design will be rejected directly as there is a simultaneous interaction
between two and above FRs with same quantity of DPs. This is because coupled design might
cause design failure. The relationship between the function requirement and design parameter
can be written as

[FRs] = [A][DPs]

The [A] will be categorized as uncouple if a matric is arranged as a diagonal matrix with the
appropriate ordering of FRs and DPs.

𝑋 𝑂 𝑂
A = [𝑂 𝑋 𝑂 ]
𝑂 𝑂 𝑋

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The [A] will be categorized as decouple if a matric is arranged in a triangular matrix with the
appropriate ordering of FRs and DPs.

𝑋 𝑂 𝑂 𝑋 𝑋 𝑋
A = [𝑋 𝑋 𝑂 ] OR A = [𝑂 𝑋 𝑋]
𝑋 𝑋 𝑋 𝑂 𝑂 𝑋

The [A] will be categorized as couple if a matrix cannot be arranged in a triangular matrix or
diagonal with the appropriate ordering of FRs and DPs.

𝑋 𝑂 𝑂 𝑋 𝑋 𝑂
A = [𝑋 𝑋 𝑂 ] OR A = [ 𝑂 𝑋 𝑂] OR any other matric arrangement
𝑋 𝑂 𝑋 𝑂 𝑋 𝑋

Figure 4: Functional domain and physical domain.

Before the design of the car started, the functional requirements (FRs) of the car need
to be determined. Those requirements basically can be determined from the main problems
defined during the earlier stage of the design process. After discovering the functional
requirement, the designers need to do brainstorming on design parameter in order to solve the
functional requirement. The design parameter is changed until decouple and uncoupled matrix
is formed. If there are two or more uncouple matrix, then the most suitable and reasonable
design matrix will be chosen and be applied for the design later. Which mean the car design
will be modified until it achieved uncoupled or decoupled design matrix according to the
method of axiomatic design.

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2.3.2 Functional Requirement of the Design

FR
To Carry Move the bricks To preserve
Store potential
approximately to travel 4m environment and
energy
10Kg of bricks distance energy

Chart 3: Functional Requirement of the Design.

2.3.3 Design Parameters of the design

A. Design 1:

DP
Use rubber
PLA Use 3 wheels Reuse domestic
bands which tied
compartment made of CD waste
together

Chart 4: Design parameters of the design 1.

Figure 5: Design Concept 1.

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 Table 2: Functional requirement and design parametric for design 1.
Functional Requirement Design Parameter
FR1 Carry approximately 10kg of bricks DP1 PLA compartment
FR2 Move the bricks to travel 4m distance DP2 Use 3 wheels made of CD
FR3 Store potential energy DP3 Use rubber bands which tied together
FR4 To preserve the environment DP4 Use domestic waste

Table 3: Matric design of the design 1.

DP1 DP2 DP 3 DP4
FR1 X O O O
FR2 O X O O
FR3 O O X O
FR4 O O O X

In this design, Lion Revenant propose to use PLA as the compartment (DP1) to carry
approximately10 kg of bricks (FR1). PLA is light-weighted and strong to carry approximately
10kg of loads. Next, by using 3 wheels made of CD (DP2) were suggested to move the bricks
to travel 4m distance (FR2). It was proposed because fewer wheels will cause the base design
to be in triangle shape which is then can contribute to aerodynamic design. Aerodynamic design
can reduce the drag friction and enables the car to move faster. To store potential energy (FR3),
rubber band were used which tied together to solve it (DP3). Finally, reuse domestic waste
(DP4) were proposed to preserve the environment and energy (FR4). By reusing the domestic
waste in daily life, can preserve the environment and fulfil the requirement which is green
vehicles. From the matric design above, Lion Revenant noticed that design 1 have an uncoupled
design matric. This means the concept generation for design is acceptable.

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 B. Design 2

DP
Use recycled
wood Use 4 wheels Use chained
materials from
compartment made of CD rubber bands
workshop
Chart 5: Design parameters of the design 2.

Figure 6: Design concept 2.

Table 4: Functional requirement and design parametric for design 2.

Functional Requirement Design Parameter
FR1 Carry approximately 10kg of bricks DP1 Wood compartment
FR2 Move the bricks to travel 4m distance DP2 Use 4 wheels made of CD
FR3 Store potential energy DP3 Use chained rubber bands
FR4 To preserve the environment DP4 Use recycled materials from the
workshop

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 Table 5: Design matric for design 2.
DP1 DP2 DP 3 DP4
FR1 X O O O

FR2 O X O O

FR3 O O X O

FR4 O O O X

In this design, the wood compartment (DP1) was proposed to carry 10 kg of bricks
(FR1). The wood compartment is strong and able to carry approximately10kg of loads. Next,
using 4 wheels made of CD (DP2) were suggested to move the bricks to travel 4m distance
(FR2). 4 wheels made of CD is being proposed because 4 wheels can make the car design more
stable and the load can be shared equally by all the tires compare to 3 wheels. To store potential
energy (FR3), the chained rubber band were used (DP3). Chained rubber band means more
energy can be stored and move the vehicle further away. Finally, recycled materials from the
workshop were used (DP4) to preserve environment and energy (FR4. From the matric design
above, they noticed that design 2 have an uncoupled design matric. This means the concept
generation for design 2 is also acceptable.

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2.3.4 TRIZ problems solving method

TRIZ is a powerful methodology for creative problem-solving (Hipple, 2003). Projects

do not always run smoothly. Even with all the analysis and data that needed are at the fingertips,
sometimes it just cannot see a way forward. At times like these, develop creative solutions is
needed. In this project Lion Revenant have brainstorm to find the solution that has been done
by other people and adapt it into problems.

Figure 7: TRIZ functional modelling.

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2.3.5 Computational Fluid Dynamics

Lion Revenants have run the Computational Fluid Analysis (CFD) simulation on both
designs to determine and analyse the effect of the environment behaviour such as air flow and
pressure on the design of the Green Vehicle. From the Solid Work simulation’s analysis,
design concept 2 shows better aerodynamic efficiency than the design concept 2. Both design
concept was drawn and extrude with actual scale and dimension in AutoCAD before import
into Solid Work for simulation analysis. With an assumption of the air velocity equal to
30m/s and being apply toward the front truck, design concept 1 shows less pressure withstand
by the truck head compare to the design two. From the simulation, the design concept 1
encounter 101.579KPa (yellow colour) while design 2 encounter 102.088KPa (orange colour)
of aerodynamic pressure. The reason that contribute to this condition is because design
concept 1 have triangular truck head compare to design concept 2 and this has improved the
aerodynamic efficiency of the design concept 1. Through the air flow modelling, it is
noticeable that the air flow diverge angle for design concept 1 is smaller than the design
concept 2. Mean design concept one can move faster than design concept 2 as the drag force
for design concept 1 is smaller than design concept 2. Therefore, it is preferable to have sharp
truck head as compare to flat truck head.

A. Concept Design 1

Figure 8: Solid Work of pressure simulation.

Figure 9: Solid Work of pressure simulation.

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 B. Concept Design 2

Figure 10: Solid Work of pressure simulation.

Figure 11: Solid Work of airflow simulation.

2.4 Evaluation of Concept

The design matric of concept design 1 and concept design 2 shows uncoupled design
matric which is desirable for the product development. Therefore, it is necessary refer to the
main problems at the earlier stage in order to choose the best conceptual design among these
two uncouple design matrices. The main problem is to design a green vehicle that can carry 5
bricks and travel for a 4 m distance using rubber band as the mechanism to generate movement.
Green vehicle means the vehicle should use high portion of recycle material instead of PLA.
Thus, Lion Revenant propose the wood as our body compartment. Besides, using 4 wheels
made of CD would be more stable compared to 3 wheels tires. This is because the more the
wheels the stronger the friction between the asphalt and the wheels. Stronger friction will
enable the wheels movement to synchronize with the rubber band while storing energy.
Therefore, the car can move backward to store energy until the point before plastic deformation
occurs. If the grab force between the asphalt and wheel is weak then it is difficult to move the
car backward to store energy. This is because the elastic energy in the rubber band is greater
than the frictional force between the asphalt and wheels. The design concept with 4 wheels is
more desirable.

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 On the other hand, Lion Revenant proposed to use the chained rubber band instead of
rubber band that tied together. This is because chained rubber band can store more energy as
the amount of rubber band can be increased to the chain if the energy being stored is insufficient
to move the car. Chained rubber band means the length of the rubber band can be increased,
the longer the chain mean more energy can be stored. Next, by using the recycle materials from
the workshop instead of domestic waste is due to it availability. Most of the materials can be
obtained in the workshop which mean there is no need to purposely go to collect the domestic
waste in daily life. Fully make used of the left-over materials in the workshop also can reduce
the scrap rates in workshop.

Finally, for the air flow and aerodynamic pressure simulation of the design, Lion
Revenants notice that design concept 1 give better simulation compare to design 2. Since the
moving speed of the prototype is not very quick then it would not bring concern effect to the
design. Therefore, Lion Revenants decide to choose conceptual design 2 to develop our product
as it is more suitable compare to conceptual design 1.

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3.0 EMBODIMENT DESIGN
Embodiment design is a major phrase in the engineering design process, which the main
engineering concept of product design is developed according to product design specification
(PDS) and economic criteria to a stage where subsequent detailed design can lead directly into
production. During the embodiment phase at the latest, designers must determine the overall
layout design including general arrangement and spatial compatibility, the preliminary form
designs which consists of component shapes and materials and the production processes, as
well as provide solutions for any auxiliary functions. During all of this, technological and
economic considerations are of paramount importance. The design is developed with the help
of scale drawings, critically reviewed, and subjected to a technical and economic evaluation.
There are 3 concerned parts in the embodiment design stage which is product architecture,
configuration design and parametric design.
Embodiment Design

Product
Architecture
Configuration
Design

Parametric Design

Figure 12: Subsystem of Embodiment Design.

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3.1 Product Architecture

Product architecture is the scheme by which the functional elements of the product are
arranged into physical chunks and by which the chunks interact. This links architecture to
system-level design and the principles of system engineering. Architecture also has profound
implications for how the product is designed, made, sold, used, and repaired. Architecture is
very important as it influenced the assembly stage.

Figure 13: Schematic diagram.

Figure 14: Indicator for schematic diagram.

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 Figure 15: Decomposition of the product.

It is undoubtedly that all the modules are significant to successfully move the truck.
The storage module which consists of the truck body is to accommodate and carry the load.
Next, the holder module which includes truck base, wheel and shaft hold the truck body, entire
truck and rubber band respectively. Besides, the power generator module that is rubber band is
the only source of power to move the truck with loads. All the components can be classified
into the system, sub-system and components accordingly.

28
3.2 Configuration Design

Configuration design is a form of design where a set of pre-defined components is given,

and an assembly of selected components is sought that satisfies a set of requirements and obeys
a set of constraints. Design specifications are separated into functions, performance goals and
constraints. Starting with design specifications, a skeletal design comprising essential functions
is first configured. The process of mapping functions to physical devices is interleaved with
the function decomposition process. The level at which a function is mapped to a physical
device is directly related to the stringency of performance goals and constraints. Configuration
design issues, such as function sharing, detail resolution of the building blocks and the possible
explosion of the number of feasible permutations, are also discussed (S, 2007).

3.2.1 Configurate Product

Table 6: Decomposition of components.

Generalized Component Decomposition Element
Standard Part  Plywood
 Perspex
 Rubber band
 CD
 Nail
Special Purpose Part  Aluminum hollow tube
 Bolts and nuts
 Bearing
 3D printed component (PLA)

Standard Subassembly Part  Light decoration

29
3.2.2 Configurate Parts

Table 7: Material selection, specification and dimension.

Material Specification Component Dimension Function
(mm)
Wood  Cheap Body 220*240*180 To accommodate
 Easy to the loads.
assemble Base 240*250*50 To support the
 Easy for (Length *Width body and loads.
finishing *Height)
Polylactic  Light in weight Truck Head 280*60*180 To reduce air
Acid  Able to (Length *Width resistance.
(PLA) transform into *Height)
any shape and Shaft Cap 15*45 To increase the
design (Diameter diameter of the
*Length) shaft slightly to
fit the bearings.
Shaft Ring 34*6 To cover the
(Diameter extra part of the
*Thickness) shaft.
CD  Stiff Wheel 120*20 To provide
 Perfectly round (Diameter rotational
*Thickness) movement to the
vehicle.
Aluminum  Strong Shaft 13*300 To transmit
Hollow  Resistant to (Diameter power from
Tube corrosion *Length) rubber bands to
the wheels.

30
3.2.3 Analysis and Refining

Table 8: Analysis and refining of the vehicle.

Type of Design Elaboration
Design for Function  Body - Strong, Durable, Stiff
 Base - Strong, Repairable
 Rubber band - Elastic, Energy
Efficient
 Wheel - Quiet, Safe, Stable, Enough
Friction
Design for Assembly  The part count is minimized
 Levels of assembly are minimized
 Facilitate parts handling
 Design parts with fastening features
 Use standard parts
Design for Manufacture  Only hand tools are used
 No moulding required

31
3.3 Parametric Design

3.3.1 Analysis of Forces

Figure 16: Free body diagram.

Figure 17: Top view of the base to show the distance that the rubber band being stretched.

32
 Figure 18: Free body diagram direction indicator.

Assumptions:

i. The speed is constant.

ii. Vertical aerodynamics forces are negligible.
iii. The total weight of the vehicle is 13 kg / 127.53 N. (10 kg load and 3 kg body)
iv. The coefficient of friction between asphalt and the wheel is µ=0.25.
v. The car travel at constant acceleration

Denotation:
i. If = Frictional force
ii. Ft = Thrust force
iii. Wr = Rear-wheel reaction force
iv. Wf = Front-wheel reaction force

Calculation:
A series of testing is carried out to find out the spring constant of the selected rubber band,
three different weight of items are hanged on the rubber band and the elongation of rubber band
is recorded. The data are then plotted in excel and Hooke’s Law is applied to find out its spring
constant.

𝐹 = 𝑘 ∙ ∆𝐿

𝑚𝑔
𝑘=
∆𝐿

33
 Table 9: Experimental data of a rubber band.
Mass, kg Original Deformed Weight, N Displacement,
length, m Length, m m
0.08 0.08 0.097 0.7848 0.017
0.2 0.08 0.148 1.962 0.068
0.3 0.08 0.175 2.943 0.095

Weight versus Displacement of Rubber

Band
3.5
2.943
3 y = 27.073x + 0.2722
2.5
1.962
Weight

2
1.5
0.7848
1
0.5
0
0 0.02 0.04 0.06 0.08 0.1
Displacement of Rubber Band

Figure 19: Graph of weight versus displacement of the rubber band.

Table 10: Parameters of the rubber band.

Parameters Magnitude
Original Length 8.0000 cm
Width 0.1000 cm
Elongated Length 0.1033 cm
Spring Constant 27.073 N/m
Number of rubber band 90 units

34
Part 1
Force of the rubber band stored, F = 𝑘 ∙ ∆𝐿
Force of three rubber band stored, F = 90 × 27.073 × (0.1033 − 0.08)
Force of three rubber band stored, F = 56.77 N
In this case, F = Ft = 56.77 N.

Part 2
Frictional force, Ff = µN
Ff = µN
Ff = (0.25) x (127.53 N)
Ff = 31.88 N

Part 3
Sum of the moments at the bottom of rear wheel is equal to zero,
Wf (0.18 m) – (Wvehicle) (0.09) – (Ft) (0.13 m) = 0
Wf (0.18 m) – (127.53) (0.09) – (56.77) (0.13 m) = 0
Wf = 104.77 N

Part 4
Sum of the vertical forces is equal to zero,
Wf + Wr - Wvehicle = 0
104.77 + Wr – 127.53 = 0
Wr = 22.76 N

Table 11: Summarise of the forces on the car.

Force Magnitude (N)
Thrust 56.77
Frictional 31.88
Rear-wheel reaction 22.76
Front-wheel reaction 104.77

35
3.3.2 Analysis of Linear Motion

The car is aimed to travel 5 m of distance in 10 s.

By using constant acceleration linear motions to find the velocity of the vehicle,

𝑣 − 𝑣0
𝐷𝑖𝑠𝑡𝑎𝑛𝑡 𝑡𝑟𝑎𝑣𝑒𝑙𝑙𝑒𝑑, 𝑥 = ( )𝑡
2

𝑣−0
5=( ) (10)
2

𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = 1.0 𝑚/𝑠

By using constant acceleration linear motions to find the acceleration of the vehicle,

𝑣 = 𝑣0 + 𝑎𝑡

1.0 = 0 + 𝑎(10)

𝑎 = 0.1 𝑚/𝑠 2

Table 12: Summarise of the parameters of the linear motion.

Parameters Magnitude
Distant Travelled 5m
Time Taken 10 s
Velocity 1.0 m/s
Acceleration 0.1 m/s2

36
3.3.3 Analysis of Stress

Figure 20: The weight acting on the bottom plate of the body.

𝐹𝑏𝑟𝑖𝑐𝑘
𝑆𝑟𝑒𝑠𝑠, 𝜎 =
𝐴𝑝𝑙𝑎𝑡𝑒

The surface area of the bottom plate of the body, A plate = 0.240 m x 0.295 m
The surface area of the bottom plate of the body, A plate = 0.0708 m2

Force acting on the plate, Fbrick = Total weight of five bricks

Force acting on the plate, Fbrick = (2.0 kg x 5) x 9.81 N
Force acting on the plate, Fbrick = 98.1 N

𝐹𝑏𝑟𝑖𝑐𝑘
𝑆𝑟𝑒𝑠𝑠, 𝜎 =
𝐴𝑝𝑙𝑎𝑡𝑒

98.1 𝑁
𝑆𝑟𝑒𝑠𝑠, 𝜎 =
0.0708 𝑚2

𝑆𝑟𝑒𝑠𝑠, 𝜎 = 1385.59 𝑁/𝑚2

Therefore, the stress acting on the bottom plate of the body by the bricks is 1385.59 N/m2 or
1.386 x10-3 MPa.

37
4.0 DETAIL DESIGN
4.1 Final design and Dimensions
For frontal part of the vehicle:

Top View

Side View
Front View

Figure 21: Frontal part of the vehicle.

For the compartment of the vehicle:

Top View

Front View

Side View

Figure 22: Compartment of the vehicle.

38
For the base frame of vehicle:

Top View

Side View
Front View

Figure 23: Base frame of the vehicle.

Table 13: Component of the vehicle.

Component Function Dimension (mm) Design Drawing
Combined To cover the 220*240*180
Plate loads (Length *Width
*Height)

Top Plate To reduce the 240*245*3

air resistance (Length *Width
and resist *Height)
water drops
Bottom To hold the 240*295*6
Plate body of the (Length *Width
vehicle and *Height)
the loads

39
Truck Head To reduce air 280*60*180
resistance (Length *Width
*Height)

Frame To hold the 240*250*50

Support body of the (Length *Width
vehicle and *Height)
provide
support for
movement
mechanism
Aluminium To transmit 13*300
Shaft power from (Diameter *Length)
rubber bands
to the wheels
Bearing To reduce 32*9
friction (Diameter *Thickness)
between shafts
and frame
support
Shaft Cap To increase 15*45
the diameter (Diameter *Length)
of shaft
slightly to fit
the bearings

40
Shaft Ring To cover the 34*6
extra part of (Diameter *Thickness)
the shaft

PVC Ring To separate 20*5

the wheel and (Diameter*Thickness)
frame in order
to avoid
friction
Wheel To provide 120*20
rotational (Diameter *Thickness)
movement to
the vehicle

Pop tab To hook the 25*15

rubber bands (Length*Width)
on the tips on
the shafts
Bumper To absorb 250*30*23
impact in a (Length *Width
minor *Height)
collision

41
4.2 Bill of Material
Table 14: Bill of Materials.

42
 Lion Revenant made off 80% of recycled materials such as recycled plywood, Perspex
and PLA that can be referred to Table 14. The total cost of this product is RM 60.30 where the
cost expends more to decoration and increase the efficiency of the vehicle. Survey been done
for others product that has like Lion Revenants characteristic which was Dump Truck product
from USA, Clockwork Elastic Car product from China and Huina Dump Truck product from
USA. Firstly, the Dump Truck with price RM120.00 selling price with the ability to carry
weight approximately 5 kg and powered by human. Second, the Clockwork Elastic Car that
been sold with RM11.00 but by only using the material of recycled box, the car cannot carry
the load. The last comparison is Huina Dump Truck with selling price RM 320.00 that can
carry weight up to 5kg load and powered by electric motor.

By comparing the entire price with the benchmarking company, Lion Revenant is more
affordable with many benefits. With the cost product only RM60.30, it can carry up to 5 bricks
which the load is approximately 10kg with only powered by a rubber band. It is friendly use
since it is separable for the body and the basic to generate power. The selling price for this Lion
Revenants is only RM90.00 per unit. 30% from the price is consider as the utility cost for this
project.

43
 4.3 Final Product Design Specification

Table 15: Final Product Design Specification for Lion Revenants.

Suggested to be used
Conditions To carry 5 bricks, move in a straight line
Moving Mechanism
Rubber band The main mechanism to move the car
Shaft Transmit power from rubber bands to the wheel
Wheel Provide rotational movement of the vehicle

Weight and Dimension

Maximum payload (kg) 13
Gross vehicle weight (kg) 3
Dimension (L*W*H) (mm) 270*240*300

Chassis
Compartment Combined plate to store loads
Top Plate To cover the vehicle
Bottom Plate Hold the body of vehicle and loads
Wheel Use 15 CDs each
Wheel type CDs

Other Features
Weather Resistant Holes on the bottom plate (no stagnant water in the car)
Truck Head Aerodynamic design to reduce air resistance
Environmentally friendly Made of over 80% of recyclable materials
Safety features Bumper (absorb impact in a minor collision)

Selling Price RM 90.00

44
 Lion Revenant’s ‘Green Vehicle’ is a truck that was made almost 80% by using
recyclable materials, such as CD as the wheel, wood scrap for the body of the car, scrap metal
for the shaft of the car, the Perspex for the base and so on. The frame support of the car was
made by scrap plywood that was taken from workshop. The function of frame support was to
hold the vehicle and provide support for movement mechanism. The dimension for the frame
support is 240mm length, 250mm width and 50mm height. There were a few components that
were attached to the frame support such as the shaft, bearing, and the mechanism that going to
move the car which is the rubber bands. To transmit the power from rubber bands to the wheel,
Lion Revenant uses hollow aluminium shaft. The elastic energy from the rubber bands is then
converted to the kinetic energy to the shaft in order to move the car as the shaft is connected to
the bearing. The dimension of the aluminium shaft is 13mm diameter × 300mm length. The
function of the bearing is to reduce friction between shafts and the frame support, not only that
bearing also help the shaft the move the wheel. The diameter of the bearing is 32mm diameter
× 9mm thickness. To meet the requirements from the company which is used at least 4
components that are made from 3D printing, Lion Revenant made a shaft cap to increase the
diameter of shaft slightly to fit the bearings. The shaft cap dimensions are 15mm diameter ×
45mm length. To make sure the wheel does not move too much, Lion Revenant attached shaft
ring which is 34mm × 6mm to the wheel. Then, there were PVC ring to separate the wheel
from the frame, so that they were not attached to each other. Next, the wheel, there were four
wheels. The wheels were made from CD that was attached to each other. There are 15 pieces
of CD for each wheel.

Then, for the upper part of the car’s body, to support the bricks and the other upper part
of the car, there was a bottom plate that was made from Perspex. The Perspex has holes on it,
the function of these holes is to make sure that were no stagnant water in the car. The bottom
plate also there to make sure the bricks were holding properly. The bottom plate dimension is
240mm length × 300mm width × 6mm height. Next, to make sure those bricks were not falling
off from the car, Lion Revenant makeup 3 walls that were made from plywood, the right and
left side and the backside and this 3 sides were combined. The right and left side of the wall
has two rectangular holes on each of them. The functions of these holes are to make it easier to
place the brick. Then, the truck head, the truck head were made from PLA (3D printing). The
truck head was there to protect the vehicle from in front. The truck head is in aerodynamic
shape, with this it could minimise the drag force and can reduce the air resistance. Lastly, for
the upper body of the car, there was the top plate. The top plate act as the lid of the car, the lid

45
can be open and close. With this, it makes it easier to place the bricks and to take out the bricks
from the car. They also needed to protect the bricks and the car.

The car has been tested several times for safety and to meet all the requirements. Then,
after all the tested and trial, the car is indeed to be safe and ready to be races and able to perform
well. After all the trial, Lion Revenant tried with many different ways to attach the rubber bands,
number of rubber band and so on just to make sure the car can move smoothly and fast without
any problems. Then, the Lion Revenant came out with the solutions to make one loop of rubber
band between the shafts. One loop of the rubber band has four chains and one chain has 10
rubber bands each. So total of rubber bands in one loop is 40 rubber bands. For this car the total
of rubber bands use is 120 rubber bands for 3 loops. With this, the car surely moves faster and
smooth. And the average travel maximum for the car is around 5 meters. Then, the car also can
carry the 5 bricks which approximately 10,000 grams of load and can move along with it.
Overall, this car was made of over 80% of recyclable materials with the selling price only
RM90 which is affordable.

46
5.0 CONCLUSION

Based on the project that were conducted, there are a few things that can be learn as an
engineer. The main thing from this project that can be learned is on how to be a good designer
that can meet the customer requirements and be advanced in the engineer world. Before we get
into deeper in the process, we must know the main of the design process, there were 3 phases
in design process. First phase is the conceptual design. Second, the embodiment design and
lastly the detail design. In this project, we can learn about the steps that must be followed while
designing a product. The first step is to define the problem, defining the problem will make all
the designing process run smoothly. Next, is the information gathering, the main purpose of
designing a product is to meet the customer requirements. Without knowing what the customers
want, the design process cannot proceed. There are two sub-topic under the information
gathering which are external and internal information. Survey, benchmarking and research
were used for information gathering under external information. For internal information, the
members of Lion Revenant were brainstorming ideas for the individual part and all the ideas
were combined through a meeting of the group. The third step in design process is the concept
generation. There are 5 sub-topic under the concept generation. The first one is the axiomatic
design, then functional requirement of the design, followed by design parameters of the design,
TRIZ problems solving method and lastly is the computational of fluid dynamics. After that,
we move to the embodiment design, in the embodiment design there are two sub-topic which
are product architecture and configuration design.

Embodiment design is a major phrase in the engineering design process, which the
main engineering concept of product design. For this project, two design were proposed by the
designers. Then, the parametric design, under parametric design there were analysis of forces,
analysis of linear motion and analysis of stress. Next, the detail design, detail design is needed
to show the actual dimensions of the product. The final process of the design process is the
bills of materials and the final design and dimensions. In the final design specifications, were
include the conditions, moving mechanism, weight and dimension, chassis and other features
such as weather resistance, truck head, environmentally friendly, safety features and the selling
price. The final selling price is at RM90.00.

While doing this project, there are some problems that we faced, the main problem was
the car can travel only for 2.5 metres. To fix this problem we referred back at the design
parameters of the design. The functional requirement of the design is to move the bricks to

47
travel 4m distance and the design parameters of the design is use 3 wheels and use rubber bands
that tied together. The wheel that made from the CDs got no problem, so we decide to change
the way attached the rubber bands. After some discussion and testing we finally can make the
car travel for 4 metres.

From the research we did, we found some competitor in the market. Firstly is the
Dump Truck, followed by Clockwork Elastic Car and Huina Dump Truck. From the research
and benchmarking, we found out that our product are more advanced than those three product
in price, materials, and design specifications. For benchmarking, House of Quality were used.
The main objectives of this project are to construct a ‘Green Vehicle’ that is capable to
transport maximum 5 concrete bricks within specific dimension of the range by using
recyclable materials were achieved successfully.

48
6.0 REFERENCE

Automobile History. (21 August, 2018). Retrieved from History:

https://www.history.com/topics/inventions/automobiles

Griffins, J. (2017). Learn about Embodiment Design. Retrieved from sciencedirect:

https://www.sciencedirect.com/topics/materials-science/embodiment-design

Hipple, J. (20 October, 2003). What is TRIZ and How can it be used in Problem Solving or
Brainstorming? Retrieved from InnovationManagement:
https://innovationmanagement.se/imtool-articles/what-is-triz-and-how-can-it-be-used-in-
problem-solving-or-brainstorming/

J, C. (July, 1997). Information Gathering: A Critical Step for Quality in the Design Process. Retrieved
from ASQ: http://asq.org/qic/display-item/index.html?item=12126

Mital, A. (2014). Learn more about Functional Requirement. Retrieved from ScienceDirect:
https://www.sciencedirect.com/topics/engineering/functional-requirement

Najib, N. (2004). Application of Axiomatic Design to the Toaster Design. Sarawak: Universiti Malaysia
Sarawak.

Nobel, M. (n.d.). Product Concept Generation. Retrieved from Electrical and Engineering Design:
http://sites.tufts.edu/eeseniordesignhandbook/2013/product-concept-generation/

S, K. (2007). Engineering Design. General Framework for Configuration Design: Part 1—

Methodology, 277-289.

Wood, K. (Jun, 2009). Retrieved from Research Gate: https://www.researchgate.net/figure/6-3-5-

Concept-Generation-Process-3_fig5_267840439

Ling, S. J. (2019, September 22). Elasticity and Plasticity. Retrieved November 26, 2019, from Physics
LibreTexts:
https://phys.libretexts.org/Bookshelves/University_Physics/Book%3A_University_Physics_(
OpenStax)/Map%3A_University_Physics_I_-
_Mechanics%2C_Sound%2C_Oscillations%2C_and_Waves_(OpenStax)/12%3A_Static_Equili
brium_and_Elasticity/12.4%3A_Elasticity_and_Plasticity

49
7.0 APPENDICES

Figure 24: First page of Survey Form with 105 respondents.

50
Figure 25: Second page of Survey Form with 105 respondents.

51
Chart 6: Results of the Survey.

Chart 7: Results of the Survey.

52
Chart 8: Results of the Survey.

Chart 9: Results of the Survey.

53
Chart 10: Results of the Survey.

Chart 11: Results of the Survey.

54
 Figure 26: First page of the brochure.

Figure 27: Second page of the brochure.

55
Figure 28: Testing of rubber band.

Figure 29: Testing of rubber band.

56
Figure 30: Testing of rubber band.

57
Figure 31: Materials that been Purchased.

Figure 32: Recycled Materials

58
8.0 DECLARATION
We hereby certify that the material, which is submitted in this project, is entirely our
own work and has not been submitted for any academic assessment other than as part of the
assessment procedures for program Bachelor of Mechanical and Manufacturing Engineering
(WK18).

NO. NAME MATRIC NO. SIGNATURE

1 Darren Ling Jie Nguong 60607

2 Ng Boon Kiet 61728

3 Thian Ann Shen 62798

4 Nur Eizzatie Akmal Binti 63592

Md Ezam

5 Nurul Amira Binti Othman 62211

DATE: 06th December 2019

59