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A host of methods and tools to support designing are being developed in Cambridge EDC. These range from tools for design management to those for the generation and selection of design ideas, layouts, materials and production processes. A project, to develop a device to improve arm mobility of muscular dystrophy sufferers, is undertaken as a test-bed to evaluate and improve these methods and tools as well as to observe and modify its design and management processes. This paper presents the difficulties and advantages of using design methods and tools within this rehabilitation design context, with special focus on the evolution of the designs, tools, and management processes.

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A novel test method for the characterisation of flexible forming processes is proposed and applied to four flexible forming processes: Incremental Sheet Forming (ISF), conventional spinning, the English wheel and power hammer. The proposed method is developed in analogy with time-domain control engineering, where a system is characterised by its impulse response. The spatial impulse response is used to characterise the change in workpiece deformation created by a process, but has also been applied with a strain spectrogram, as a novel way to characterise a process and the physical effect it has on the workpiece. Physical and numerical trials to study the effects of process and material parameters on spatial impulse response lead to three main conclusions. Incremental sheet forming is particularly sensitive to process parameters. The English wheel and power hammer are strongly similar and largely insensitive to both process and material parameters. Spinning develops in two stages and is sensitive to most process parameters, but insensitive to prior deformation. Finally, the proposed method could be applied to modelling, classification of existing and novel processes, product-process matching and closed-loop control of flexible forming processes. © 2012 Elsevier B.V.