So, good afternoon all of you and welcome to the course design, technology and innovation.

This course is a
combination of three large sorts of areas, not even disciplines wherewe need to see you know how we can
come up with innovation using design and technologythat is our major [Link], for today's class we will
consider the Jaipur foot as our case study. Important aspectof the Jaipur foot is that it is prosthesis. The
prosthesis are different from ones whichare put inside the [Link] are which are artificially they're
supporting the body from external aspects when thereis an amputation or in some deformity in the legs or in the
[Link], this Jaipur foot is an extremely unique design and according to me one of the bestinnovation
examples in the [Link] was started very interesting collaboration between a craftsman called Ram C
Sharma whowas you know basically building polio calipers for children and he observed a bicycle onthe road
and said why can’t I make a foot as strong as the bicycle tyre from [Link], he started building wooden
mock-ups because he is already working in the SMS medical collegein [Link] had this orthopedic surgeon
Dr. P K Sethi, so he would go to the doctor and say I amworking on [Link], the doctor would give him all the
anatomical details: what type of system should be done,what type of gait the leg would [Link] all those
details he would [Link] both of them together built multiple samples so there is an initial node
development whichhappened. So, basically the Jaipur foot will have three major [Link] prosthetic
foot is the most critical one in this [Link] knee joint if it does not you know upward amputation the
above-the-knee amputation youwill have a knee [Link] a socket and shank to fit the thigh areas;So, below
the knee prosthesis, you will just have the foot and the shank which will fitinto the leg. In 1969 they started, but
it was not going forward. They were doing some10 or 20 prosthesis for various you know patients who would
lose their limbs and it didn't youknow really scale [Link], the scaling up was done by Dr Mehta who was an IAS
officer who took special interestsin the Jaipur [Link] he has to, he had to pick it up from the hospital and
make it into a society and hesaid ‘I am going to provide this Jaipur foot free of cost and the quality will
bephenomenally good’, and then since then you know with this has been a [Link], interesting situation is
that the doctor and the craftsmen team kept the Jaipur footat a very low volume level, not because the Jaipur
foot did not have the potential, justbecause of the human tendency of not understanding how you can scale up
whereas an IAS you know,an Indian Administrative Service, you know retired professional would actually talk
aboutscaling right, talk about reaching more number of people. So his whole strategy was how canI make this
reach across the world you know across the country to all the you know peoplewho were [Link]
have the dancer from you know Andhra there was a movie called Nache Mayuri and she actuallydanced in a
program and there was a large movie and that made it very popular. Everybodygot to know about it and you
know a lot of people started coming to Jaipur to get thefoot. So, that is how the whole journey started and our
interest in the product came [Link] I visited the place; I got a phenomenal insight on how this Jaipur foot was
helpingthe poorest of the poor in the [Link] people who get amputated generally are farm laborers, truck
drivers, salt pan [Link] me why would a salt pan worker have an [Link] panning, making salt,
infection from any cuts or wounds in his leg while beingon the sand. So, that infection can cause gangrene and
then they would need to amputatethe leg. Lot of people are like that. So you know that is a very good case for
us to considersalt pan workers where else you see you know standard cases of [Link] machinery.
Sir: Heavy machinery, very good, heavy machinegenerally, you have amputated arms, legs in heavy machinery
little, little less but itis there. And truck driving and you know accidents are more common you know for the leg
[Link], here you can see the person walks in. He gets the [Link] he goes back the same day
[Link];All this is done because of the association: The Bhagwan Mahaveer Viklang Sahayata
[Link], the vision of BMVSS you know is that, you know, they want to actually give boththe physical,
economical and social rehabilitation. The whole organization which build that typeof system because the
people who come, is very important, the people who come are extremelypoor, in fact, most of them who come
do not even have their breakfast. So, when they comethey give them food. For the everlasting credit of D R
Mehta, that IAS officer he said ‘Chakravarthydid you observe that these people who come do not have one
disability. They have threedisabilities’.One is amputation. The second is they are extremely poor, because why
they got amputatedI believe, they were out of work for six to seven months while they were recuperatingwith
the operation or with the leg and they would their, all their finances would havedwindled and then the third
disability is that they were illiterate. They only had askill. The large number of people who would come 90%,
95% of [Link], I need to tailor make the design to suit the design of the complete system to see thosetype of
people. If I identified only one disability as handicaped then I would do anything inthe world. Let me give a
small example over [Link] had Abdul Kalam who was the very senior scientist at the defense metallurgical
ResearchLaboratory much much [Link] went to the Jaipur Center, Jaipur foot center and he said my god
this Jaipur footis very heavy because I am coming from the context of metallurgy and fiber reinforcedplastics
and polymers and all those [Link], he said ‘I have all these technologies in Defense Metallurgical Research
Laboratory(DMRL), why can’t I use it for the benefit of the people?’ Very noble thought, ok?So the project was
given to [Link] DMRL came up with this fabulous carbon-fiber shank to be mass manufactured in the
factory,then made the foot design, the best possible rubber and that's it. And it is in the showcaseof DMRL
even after 25 years now. I'll tell you what happens there. It is very interestingthat it is not just technology or
research or value proposition, it is about the combinedeffect of the situation for which the product is being
[Link] small component in the product from the cost, from the customization, from thedelivery, from the
mechanism, from the deployment, everything is very important. Just imaginethat prosthesis was costing thirty
thousand rupees and the Jaipur prosthesis was justtwo thousand rupees. D R Mehta would said ‘I would
actually fit with two thousand,I will rather fit fifteen people rather give one to one high-end prosthesis to one
[Link], I will save fifteen lives rather than saving one life’.So, he didn't pick up the technology. So, this is the
interesting study where I am tryingto say that you should not come from your perspective for any of these types
of veryinteresting studies of innovation. You need to very, be very focused from the perspectiveof the end-user.
Whom are you know working for? So, that is the issue about, the socialrehabilitation for the [Link] let me
show you a video on how the thing is manufactured. You all observe it closelyof how the whole aspect of the
you know aspect of the details I told you about customization,about finishing it off one day, type of
manufacturing, what all is happening you know I like to runthis video for you. So, this is the centre in
[Link] come in. They are sort of, they are taken in one by one. Everybody comes in you knowto take their
cards and a very simple process of using a plaster cast to get the exact mappingof the stump. Then you make
a knee cast out of the female thing and you have the stumpwhich is your exact replica of your lower knee
prosthesis. And then you use, you know,the process of plastic forming and he is now adding the leg part to it so
you add the PVCto fill plaster in that, so they get the complete leg [Link] these are those high-end or you
know of no polyethylene pipes which are heated. Whenyou heat plastic, thermoplastic, to a temperature they
become malleable, they become [Link] you know get the size into shape and then you come down to the
bottom parts where singlesingle plastic, you know, small small parts, various, you know, fingers are put
togetherbound by rubber and then you know put into the dye and then pushed into the vulcanizingmachine
which is the [Link] here you have you know after the vulcanizing you have your foot piece ready. So, once
thefoot piece is ready so you got the whole pipe ready and then it is fitted onto a human bodyand then you
know the person then goes home with the leg. So, this whole process happensin a day because the BMVSS
has done all the planning of keeping all the parts ready, manpowerready, who know how to, you know handle
these types of large numbers of people and takethe thing you know forward. So, there are a lot of things
happening, a lot of testshappened, the whole world stood up to this innovation thinking that there is
somethinggreat about this part because this leg, the prosthesis was better than the imported prosthesisin
multiple [Link] me one thing if this prosthesis was costing two thousand (rupees) and it is better thanthe
prosthesis from Germany’s Ottobock or the American prosthesis, what do you thinkis the reason?Any guess?
Sir, one is that it looks like a human [Link]: Very good, one sure short thing is it’s exactly the human foot, but
that doesn't giveyou that type of advantage. It’s cheaper so more people can easily getit. Sir: More people can
get it. That is alsoa very very good point. It's customized for the [Link]: Very good. Hit on the nail. The top
mark is for customization, what happens in theInternational prosthesis they make sizes: Small, Medium, Large,
[Link] whatever sizes you make when you put on your stump it will be loose. It will neverfit exactly to the size
of your stump. So, what happens. This is a prosthesis. Walking,so much of movement, so the scaling happens
on your stump, you get sores on your [Link] that problem, get further component they stop using the
thing. And if you get a swollenstump you cannot use your prosthesis it is extremely [Link], look at the
beauty of the design. This design with the limitation and the hard workof bringing all the people together, rather
than sending the prosthesis to various locationsyou bring the people in, right? It's completely reverse of an
international, you know, supplychain activity. So, by doing that you are getting something which is highly
valuablefor a product like a [Link] I trade off, I would trade off mass production to customization, got
it?Sir, so you said it was custom made, so is there any part that is pre-made, the partthat is not attached to the
stomp? Sir: Very good question. It is customizedbut the customized part only is the stump, stump. Whereas the
foot parts are all readilyavailable. Whereas the pipes are formed as per the heights of the people. So, only
thecustomization part is the; is it pipe assembly. The formed you know stump assembly, okay?So today, you
know, it’s the most widely used prosthesis, people run, people [Link] performance it is more closer to the
natural [Link] here when you do a standard prosthesis you cannot bend your leg. The amount of
bendingyou can do in this leg. Okay?So, here we have customized fitting of the leg, better than the imported
prosthesis,the biggest advantage comes that you can work in your salt pan lake, because it is
completelysealed. Look at the bottom it is rubberized silicone rubber so you go in a salt pan lakenothing
happens to it. The top is highly chemical resistant, polyethylene pipe so that is alsoyou know very, very good for
your [Link] then, you know, people can work in agricultural fields, paddy fields and there is no issueat all.
And the best part is that you know you can go barefoot. So, it culturally matchesour requirements of sitting on
the floor, going to temples, you know and multiple aspects,which made the costs go down [Link] the
production happened at large [Link] me when it is nonprofit, lot of people donated, huge amount,
organizations [Link] our Minister of Welfare Government, came back and said, ‘Wow! you did a great
job,can I give you money?’ So, you know, that way there was a lot of service to the underprivilegedand the
handicapped people. And the key to the success in all this was meeting a commongoal. Remove the three
disabilities, I was saying, meeting the three disabilities inthe best possible [Link] me, how will I meet the
disability of being extremely poor? What will I do there?It's low-cost but he is not spending money. So, they
thought up till that level, theysaid ‘My god this person is already was in the hospital, he has finished all his
resource,so he sold his one acre plot, he has got nothing to do.’ So they thought about all that andactually they
rehabilitate them by giving them cycle rickshaws, this is most probablyfor the, you know, people with the hand
[Link] work with them also while they manufactured the Jaipur foot they would manufacture
cyclerickshaws and also give [Link] set up a separate factory to give them the rickshaws for you. Once
you have mobilityyou could have a lot of work and you know they can pedal and take it [Link] them job
training and women would be you know given sewing [Link] some of the men would be given the tea
shop kit.I was completely sort of you know floored when I saw that while they were going outthey were handed
over these you know kits which just would cost 2,000 bucks or thousandrupees in the whole and you know they
would go out empowered to lead the life as it isis very traumatic, the whole family is depended on this one
breadwinner and you know he isnow the whole family you know takes in to the next [Link] organization
like this, when I have been working with Jaipur foot for the last10 years, a lot of IITs, a lot of large institutes,
large companies start coming in very, [Link] have some of the best gait labs set up at Jaipur in the,
you know, center for prosthesisand [Link] have donated heavily for, you know, study of various
aspects of below the kneeand above the knee [Link] then, as usual you know, we had lot of
philanthropists you know, Ratan Tata, thenthen the US Secretary of State commerce: John brassA lot of these
interesting visitors would come and because of that what happened thevisibility increased and more and more
technology started getting used.

Then what is beauty of this is that they have used very, very high technologies in thisand the hit on the nail was
that again D R Mehta’s brainchild of making it completelynon-profit. It is a very, very complex phenomenon. You
cannot just take a cast and, you know,put a pipe. You need to have special laser machinery, so the laser
measurement measuringdevices were brought in from Germany. So, as soon as the patient comes they make
himstand on a wall and the laser measures his, you know, whole body and his gait positionand then they would
take the dimensions from the laser-guided points and then make [Link] even a small five
millimeter difference in the way, you know, you work on the prosthesiscan be very detrimental to the comfort
and to the walking [Link], you know, thanks to all the visitors and the promotion which happened with the
[Link] then because of accidents in Afghanistan and other places, land mines and all, theyhave set up
huge Jaipur foot organizations across the world now and this is the innovationpart of our whole course. Till the
benefit does not reach millions of users and delightedusers, we cannot say innovation has [Link] can
see how many countries the Jaipur foot has, you know, gone to the limbs itselfhas gone to more than 5 lakh
13,000 people and 20,000 people across the world have setup offices 2016 [Link] then, you know, lot of
professors like Prof. C K Prahalad showcase this whole innovationas one of the best innovations for the bottom
of the [Link] calls his book ‘The Fortune at the Bottom of the Pyramid’, so here we very clearlysee that
every year, you know, 16000 prosthetic fittings are put in. It's a huge number to,you know, work on and take it
forward. So, the video I am going to show you now is doneby C K Prahalad, his student, a lot of his students
and staff came down to India studiedthe whole phenomenon very effectively and what I like about it is it
captures, in avery short video, it captures the complete, you know, whatever I have been talking tillnow, all the
aspects of the Jaipur foot very [Link] there we are, we you know, saw this film made by C K Prahalad and his
project [Link] I visited, you know, there I found one person who came with the screws which havecome
[Link] the shank, the screws had come off and he had nailed it. So, what happens when younail a plastic? It
will crack, this is the most important [Link], then we did a project in IIT. Worked for six months to design the
screw. Can you nowguess the screws going through how many materials? Skin colored cosmetic rubber which
is, youknow, the vulcanized rubber compound and the wood and the foot and the plastic shank. So,what used
to happen is through the screw water used to seep into the wooden part, throughthe screw, through capillary
action and the wood will start getting soft. So the screwget loose and it would come [Link], then we found out,
you know, this best screw that we researched, we found out thecorrect rake angle talking to our mechanical
engineering professors. We came up with astainless steel screw. We gave the right drill hole so that the
stainless steel screw willfit right into all the 3 parts and then we also gave a sealant, that is once you drilla hole
you put a sealant drop so that the wood gets sealed over there before I drivethe screw [Link] we supplied that
to Jaipur and they tried testing 200 of these, you know, screws whichwe sent and if that works then we would
put those screws everywhere. So, every small,you know, maintenance issue can be taken in a very good way
so we need to be sending thatand that is a small contribution into this large [Link] 3 sections here: the
Finger section, Mid foot and the Heel. So these 3 sections areseparate where, you know, construction also is
like the foot. So, the beauty of this designis it can bend. It is beautiful, the type of load, it can bend, it can take
all theshocks of jumps and, see how it is [Link], we saw that the affordance is happening because it is
reaching, and it's the way itis manufactured, the whole structure of strategic management happened because
of the, you know,[Link] then it is maintenance free because it is single, there 2 pieces: the single piecefoot
and the shank. So the maintenance is very, very [Link] saw that stocking which is there on the stump, the
stocking is specially double woven,you know, cotton stocking which actually gives all the cushioning to the
stump it plays avery very vital role and that also I believe comes from Germany because of donations
fromGerman counterpart who wants to, you know, give those stockings to [Link] is irrigation pipes most
probably HDPE so these pipes are extremely strong becausethey use for piping water for agricultural
applications, so that is a very importantcomponent of the design. Is this high-tech? What is the high-tech aspect
of this?Very good. Material. Which material is high-tech here? Of course the microcellular rubberyis high-tech.
Why? Because it went through all that research to be produced and, youknow, available in large sheets which
are used for large applications outside in carindustries and other industries as, you know, suspension bushes
and other places and hereyou are using the best research from automotive to use it in Jaipur foot, but you are
usingit in a customized way. Excellent!What are the other high-tech things in this? High-tech materials?The
socket. Very good. The socket again is extremely [Link] comes from the best polymer, largest companies,
very good strength, very good [Link] is a thermoplastic material so you heat it and you very nicely shape
it right so thatis one, you know, excellent [Link] the third interesting aspect is the rubber cord and the
vulcanizing paste and the rubberwhich is used, comes from the tire industry. And can you imagine how much
research thetire industry would do to generate these raw materials? Very, very high quality raw [Link], I
am using the high tech aspect in this is all in the raw [Link] this wooden block, the grains of the
wooden block has to be in the right orientationso that the screw will not come off. Wood can give you
tremendous amount of shock absorptionat that level. And what else? The joint. It can give you very good
compression for puttingthe screws in and locking it. So, that is the beauty of putting, you know, all the aspectsof
the, you know, high-tech into this simple [Link] every aspect in the Jaipur foot has multiple advantages,
not one advantage. Microcellularrubber, what all it’s doing? It’s giving me cushioning, it is giving flexibility, itis
giving it moldability, moldability now I mean building the model and it is givingme longevity, because
microcellular rubber is non-perishable. Here, see it is all skill,skill of the people who are getting the job done.
So, the final fitting and the finaldesign they actually do it very customized to the people who are [Link] saw
they were actually heating on the, you know, heating on a heater to, you know,get the shank into the rubber.
So, there is a joint there and it actually they fully fitit in as per design they have an area that goes fully in and
they drill the hole afterthey fit the shank, through and through. So, they completely fit it, drill the hole andthen
pull it together. So, their size is already measured. They know the sizes and they doit and that is the whole
reason that they do not have too much of standardization. Thereis another problem of accurate [Link] they
are working on that, how to modular design so that they can really close in onthe, you know, inaccuracies if
they crop up in the design. But this is all again handskill which is coming into [Link] will have to come up with
some design so we came up with a design which is likea collar, so you push the pipe and it goes and rests on a
collar on the foot so we madea collar here, it is still not implemented we gave that design where you made a
collar,so when you put the shank it exactly goes and sits like a socket like a tiffin [Link], we made that, you
know, so that there is no sort of dimensional problem becausesometimes it is heated more it can’t go in. So, we
worked 4 months on that and wesent the design. And what is interesting in all this is, it is like again Abdul
Kalamnow, I sit in Bombay and send in design. Will it get implemented?It is a large organization right? It is a
large training. So, it has to be an activistmode. You have to be there, you have to train the people, you take
things forward then onlythings get implemented. So, we are planning to take it up, you know, in the next
sessionsand get the whole, you know, thing [Link] small finger blocks microcellular rubber, they
were cutting with their hand. It's avery tedious [Link], we want to help them out and he said ‘we’ll give
them punching machines to cut exactlythe size of the fingers’ so that, you know, input was given by us so we
are working onthat also to support the production aspects of the [Link] rubber cords again from tire
industry provide strength and resilience. You are tellinghow will, by weight, it will come back? Look at the way
the tire is designed, it is thesame way the foot is designed, look at the strings which are, and all these are
placed,you know, in the right orientation so that you can get the type of resilience you [Link] are coming,
all of them are coming on top of those, you know, finger blocks so,then it gets molded with the cosmetic rubber
it all gets sealed and this actually generallyis 20% larger size, 10% larger size then the actual tool. So, when
the tool presses itthe whole thing gets compression and then the rubber flows in all the directions andyou get a
very, very solid piece in [Link] basically no skin color, now they are also trying to get little darker and
lightershades. What happens with all these organizations is when you have inventory becomes very difficultto
control, and the type of population which comes over there, you know, they are happyto get a foot. They are
really not bothered whether the color of their foot match, itis that type of, you know, sort of requirement. So, we
have to really understand the [Link] if we can give colors one of the best, it is quite good.I am now
coming to the last section of her lecture. So, we saw the whole innovation [Link] the whole
manufacturing, how the whole materials and how each material has multipleroles, multiple [Link] do
you think there are different designs all over the world? Using blade running prosthesiswhich is developed in,
you know, one of the best universities in the US and, you know,it’s program, it’s got the best materials. So,
there are innovations at every [Link] you call this innovation? It is of course innovation. It uses all the
ingredients forthat context. It could be for one user or two users, but it is happening at that [Link] we apply
that to our context? It is very difficult, because the whole ecosystem doesnot work, the cost will come too much,
we do not have the type of resources. If we hadthe resources why not, but if the resources were not there then
it is very [Link], we need to understand financial implications, but if you look at the other angle of
administrationand cause and running, that is where your innovation can never reach [Link] there are
micro processor controlled prosthesis, and a lot of work is happeningon the C leg .Fabulous designs, fabulous
technologies, you know, very good case studies on the, you know,YouTube of how these are developed and
again saved up a passion, the designers and theteams are working on for a different context which is working
very [Link] are again in integrated prosthetic legs. Surgically they have implanted. So you haveone part of
the prosthesis which is an implant into the bone. Then what will happen? Allmy outside problems remember I
was talking about customization and all, that is goneright? It is already into your bone, and all your gait will be
perfect. Your orientationwill be perfect and that operation also has to happen very effectively and then you
canattach the best, you know, computer-controlled, numerical controlled [Link] control your gait it will
learn how you walk and program itself to give you the bestgait and you cannot even make out that you do not,
you know, if you are having an artificiallimb. So, the technology and research has gone to that [Link] we
have a lot of examples of this, you know, a racing driver who had an, you know,accident and he has both his
legs of that caliber. And with that I’d like to closeand we now very clearly know what happens in the journey of
design, the technology,technology can be materials and manufacturing, and the innovation, and innovation
comes fromthe complete domain of understanding the user, understanding the strategic implication andthe
whole vision of the person who is running the show which is D. R. Mehta of : What wouldI like to do?How will I
like to make it completely philanthropic? How will I like to make it a social design?And take forward the largest
sector innovations? This is one of the best examples of innovationin the country. So, I thought we will start with
this for our whole design and technology,you know, course.

So students, good [Link] is one of my most favorite topics: User Centered Design, and we hear a lot
about UserCentered Design when it comes to, you know, online platforms, websites, buying, onlinebuying
platforms, when you have these online shopping portals because they are, you know,it immediately translates
into business like when you sort of, you know, somebody comesto your site and if it is very easy to use and he
bought something on your [Link] it is too tedious they would not buy so coming from that angle when I go and
see myproducts which are around me a lot of products are extremely tedious to [Link] of various
reasons some reasons could be that they are because of [Link] reasons could be because of
material properties and the people are not lookingat how to make these products very comfortable to the
[Link], I am talking about a physical product where helmets, which are used, on two [Link], let me tell
you a small story.I had the student Mandar Kale in 2007 I think, and he came late for a product design
[Link] is we have a P2 project where he was late for a [Link] I asked him, you know, ‘Mandar why
are you so late?’ and ‘What has happened?’He said that his friend died in a motorcycle [Link] the
motorcycle helmet was strapped to the back of the [Link] was in Pune, and he was very disturbed
because he was saying that if only, you know,my friend would have put on that helmet he would not be dead
because he had a head [Link]-on collision with the truck in the front because the truck did a sudden break
and heis going at it, you know; so then, you know, it struck me that Mandar if you are so concernedcannot we
design a product where you encourage users?That is, you go like the way you take your key, you put on your
helmet and then you go,cannot we do such a thing?Why are helmets so uncomfortable?And then we
[Link] found out so many new problems with helmets aren't so many deaths.140,000 deaths, you know, in
the year 2015 but if you go now the increasing, you know,day by day now that we, you know, fines are much
more severe people will wear helmetsbut I am just saying, why should the policeman ask for fines when you
are saving your life?So, this is the whole challenge we started with in this, you know, journey of designinga
helmet which will be extremely [Link] if you have an extremely comfortable helmet will it be
unsafe?need not be, very [Link] it not pass Indian standards?No, it has to pass Indian [Link]
talking about, today we are talking about technologies, materials and [Link] they are, we have to make
technology, we have to make materials and we have to makeour engineering process suit the user right?Not,
you know, give a manufacturer in specification that you to make these helmets, you know,like in this particular
way and, you know, there should be no ventilation and, you know,this ventilation the helmet will crack which are
not even, you know, which are not evenjustified from them to [Link], we start with that premise and we said
we have to look at the situation around [Link] this is one of my, you know, project associates in our design
studio Mr. [Link] worked with us, he was also an M. Des designer and he said it is also complex: our
culture,our ecosystem, the way we use helmet, the way we use the two wheelers, the way we useour two
wheelers and he made this wonderful, you know, sketch, you know, saying that ourhead gears you have, you
know, if you are having in head gear what will you [Link] you are having, you know, milk, if you are a guy who is
taking milk around how willyou handle it?So, we found it very, very [Link], from there on we started
and we said let us understand our culture, let us understandthe local situations and habits and let us also look
at the socio-economic [Link] the helmets are too expensive nobody will buy [Link] helmets have to be,
you know, also looking at who is using the helmet for what [Link] here we come down to a very important,
you know, topic in design which is [Link] need to have that variety of products which are suitable
for different, differenttypes of [Link] it is a myth when we say that I have designed one product and it will
be good for everybody.I take a good example of your spectacles, everybody uses a different [Link] it be
style, let it be convenient, let it be, let it be a type of choice you [Link], you need to have helmets which
are, which are that type of variety, so thatyou can choose the right helmet for your [Link] we looked
at, you know, conditions in [Link] the largest two wheeler manufacturer, is still growing.69% of the total
number of motor vehicles are [Link] to the head are the main cause of [Link] here, for
example, you will be surprised that when it is called a blunt [Link] the injury to the head happens, the
brain goes and hits the skull inside because thebrain is in a fluid and when it hits the skull the person is brain
[Link] would not see any injury outside but the person is [Link], these are the, you know, challenging
things we were facing and we are saying that anywaya helmet is the most effective way of reducing these
[Link] the majority of two-wheelers, anybody we interviewed, we found out that they justdo not want to
wear a [Link] we went and started studying our market, and our situations and [Link] is a very,
very important study for [Link] then we were watching the type of risks on the [Link] are too [Link] is
happening when you are stuck at a traffic junction the, you know, helmet getsvery [Link] us look at the
construction of the [Link] do you think saves the person's life in all these three parts of the helmet:
theshell, the thermocol which is the expanded polystyrene foam and the PU padding inside,out of these three,
which is the one which saves the life?[Link] that does not cost anything right?Thermocol is the
[Link] thermocol has a special property of actually reducing the acceleration of the head, thebrain
inside when it is going to hit the head and that type of, you know, that type of compressionloading and we are
not able to get in any other material till [Link] tried a lot of [Link] are not able to get that type of
compression where you get that type of cushioning so thatthe brain does not go on hit.I must tell you a nice
story over [Link] Delhi we were given a big task by the transport department and they told us, you know,
pleasecheck out whether these roadside helmets are good or not they selling at 400 bucks 600bucks 200
bucks and they may be very dangerous for the people who are buying [Link] we took all the roadside
helmets into our, we have a very good bio medical facilityat IIT, Delhi when I was teaching there, and Professor
Dinesh Mohan was the [Link] got these Studds helmets which are the best in the [Link] we got
the other [Link] other brands, and we bought four local roadside [Link] we put them on the testing
machine with sensors and everything and to our shock theroadside helmets were performing much, much
better.20% to 40% better than the Studds [Link] could be the reason?More [Link] another
interesting issue was that the shell which we thought was the most importantwould crack in the other helmets
and break but save the life of a [Link] roadside helmets did not use that much resin as Studds was
[Link], if you use a lot of resin the shell is very hard, it takes all, when it goes andhits the floor, what
happens?It absorbs less energy whereas the roadside helmet shell would go [Link] happens when
something cracks?It releases all, it loses all the energy and it was much, much [Link] was a shock for
[Link] thermocol, the Studds, you know, when the thermocol in the Studds helmet, was actually18 to 19
millimeters and sometimes it was curvilinear because of the style and all,they had to make it with some grooves
[Link], the outside helmet, no fancy [Link] was straightforward round shell of 22 to 23 millimeter
[Link] was the minimum, you need a minimum 20 millimeter thick for saving the life of aperson, it was 20 to
24 because, it was just because of lack of, you know, things and youwant to make a simple element there EPS
form which is the expanded polystyrene was thickerand a uniform cross-section, so it did very well in them in
the [Link] that gives us the impetus that we need to, you know, do something very drastic in,you know,
making people aware of this as well as see to that, you know, people wear [Link] then we said let us
study all the materials [Link] will we use Kevlar?[Link], very high-end and then we also
checked out other materials like lexan, lexan is apolycarbonate [Link] is very strong
[Link] should I study these high-end materials when I am designing a helmet for a two-wheelerrider?I am
not going to use them but by studying the materials we study the [Link] are studying the properties I
can come up with ideas for better use of material inmy context [Link] we always do that whenever we have
some study we will study parallel products whatevermaterials they are using, so we can come back and do
multiple [Link], here then, we also looked at an [Link] is a styrene material which is used in all plastic
scooter parts and abs is a verygood, you know, ABS is acrylonitrile butadiene styrene which is very easy to
[Link] is injection [Link], just to, you know, give you a little illustration of what happens if you are traveling
at, say,45 kilometres an hour and you have a head-on [Link] is like falling from the second-floor balcony
head [Link] is the type of impact and it is pretty severe we do not realize it, and for 45 kilometresan hour is
[Link] of us go ahead at 60 to 80 kilometers an hour and if that is the speed you shouldbe like falling
from the terrace of this five-story building there is no chance of survival, butafter the collision it [Link] it is
adding on but if I come with this, you know, standstill truck then my 45 kilometerswill become around 25 to 40,
by the time I go and hit the, because some amount of decelerationhappens when I [Link] some amount
of shock gets absorbed by the vehicle and then the movement of thebody, all that, so it reduces a little [Link],
but then you just if can imagine that if the speeds are much higher it could bevery, very [Link] that is what
we see outside, so many deaths because of that reason and that perceptionis not [Link] is a challenge for
[Link] then we went and studied the standards, and a very interesting cartel happens in [Link] the
standards we have [Link] have professor's, we have visual experts and we have also industry
representativesand unfortunately they are completely biased towards [Link] are biased towards
technology, and they are not having any context of user [Link] then all the helmet standards are
coming from cold [Link] take in the British standards and they brought it down, and all in Europe,
wheredo they use motorcycles?Racing, mountains, going, so for them and what type of weather?Very [Link]
what happens if you borrow the standards from them?Your head will get cooked in [Link] that is
what happens in [Link] the temperature outside is of 47 degrees and you are wearing a helmet on your
headyou just cannot [Link] is so hot [Link] we went and told, we then met the Indian Standards and we
told them this is not [Link] have to have a person who is responsible for the comfort of a person in your
committeeso that they look at the comfort and then introduce all the new [Link] we did lot of observations
of people's problems of, you know, how they store [Link] difficult it is to buckle and why people do
not buckle their [Link] know, that they do not buckle the [Link] what happens?Tell [Link] helmet
flies somewhere else and you hit the head, head [Link] it, and we found out that this 20% accidents are
happening, people are wearing helmetsand not buckling, it is happening because of [Link] is also very, very,
you know, serious concern of buckling [Link], here we are looking at, you know, gets very hot and muggy there
was, you know, peopleuse a cloth inside carves and, you know, lot of people, you know, drive with the visorup
though it hurts their eyes, so the air is blown inside the, inside the [Link] interaction between two people,
extremely difficult when you wear a [Link] that is a serious issue or will you improve that?There is no, it
restricts vision is a very, very clear [Link] helmet sizes are so big sometimes it restricts the vision from the
[Link], this is the most important thing of our design [Link] product [Link] we are saying that the
helmet should be easy and convenient to carry and [Link] encourage and stimulate [Link] ample
[Link] be lightweight, helmets are very heavy, that was a very important component whichpeople
did talk [Link] fit, you know, aptly on the head without [Link] of helmets will be [Link] then
provide clear vision and facilitate hearing and occupy less volume when not [Link], these are the [Link],
when you have a brief points you want to, you know, sort of, work on this briefand make multiple [Link]
problem should have an idea right?Multiple ideas together will make a concept right?Multiple concepts will
compete with each other to get selected as a best concept and thecriteria of a selection will be the product
brief, got it?So, let us see how this whole journey [Link] is this doing?Buckling, because buckling by the
[Link] just move these levers and the helmet is not coming out [Link] when you are doing ideas
remember, no questions [Link]?You did that creative [Link] the idea is there, respect the idea,
‘Yeah good solution’.Wow!I love this [Link] is the scarf idea and a lot of pillion riders, women riders would
say that they aremuch more comfortable scarfing rather than [Link] a buckling a lot of people have fear
that the buckling will not come [Link] it rusts and the buckles are very difficult to pull [Link], scarfing is
a very common way of [Link] then tell me if I put a scarf what will Indian standards say?It is not secure
[Link] good and what will they do?They will test the knot in the testing [Link] will pull and
[Link]?All that can be done by getting the type of fabric but if you want to have an idea togo to the next
level you can always do whatever you [Link] is interesting, Sweat ring on the top, because too much of
sweat is coming, so thereis a, you know, ring on the top for [Link] idea again Mandar only made all
these ideas, where you are receding sideways tomake the helmet very slim and [Link], you know, two
part receding [Link] pull them out and put them inside so it becomes like, very narrow like a small [Link]
is again a collapsing, you know, self collapsing [Link] is like all around, on the top it has got a [Link] of the
protection happens on the [Link] is again an interesting idea of [Link] have two shells you swivel and
you lock, becomes very [Link] storage [Link]?Side [Link]?This has been inspired by the sheikhs
who wear this, you know, round ring cap with thecloth, so it is inspired by that and it is like, you know, ease of
wear idea of [Link] it should be as easy as wearing a cap or just, you know, with a ring on the [Link], this is
windows on the helmet for letting air [Link] when you are the signal you can actually open the ventilation
ports or they can bringout the helmet so that you get the breeze [Link], you know, inspired by various
[Link], different ways of sort of air [Link], that your air, you know, is the; you are very, very
ventilated [Link] different types of dimples so that your air channels are formed so your head is
coolbecause of the venturi [Link] from the sides if possible;This is a helmet with padding on the
[Link] those people sitting next to each other and want to [Link] helmet actually hurts quite a
bit.A lot of people complain that they would dash against the helmet when there is a pillionrider who wants to
talk to the front because of the, very easy, so the padding on the [Link], each problem you will come with
an [Link] challenge is pollution, so much pollution that if it is an integrated helmet with apollution mask it
can be [Link] if it is easy to store very good, so we can think of a collapsible [Link] then these
are only very few ideas we [Link] had some 150 ideas.I will show you some of the [Link] what
happens when you have a lot of ideas like this, you know, you very clearly we arecoming down to the first three
points which is talking about comfort of use, encouragementof use and regulation, right?So, automatically when
you cluster ideas these types of situations will come forward to [Link], we had a ventilation cluster that is I put
all the ideas which talked about ventilationas a ventilation cluster.I put all the ideas on the board, we actually do
allotting, which was the storage cluster,easy to store [Link] all the ones where it is easy to [Link] talk
about motivation and, you know, less resistance to use a helmet that we put inthe ease of wearing [Link]
at this ventilation [Link] is put in this cluster because it has a chance of ventilation [Link] was going to
the folding [Link] you can actually bring a couple of ideas [Link] at the window idea, look at the
gaps, look at the [Link] of ideas are put together and then what you do is, you actually use all those
[Link] example these split ideas were also used; the lure ideas also were used inside for [Link]
ideas where you are opening, remember that side openings were also [Link] when you build an idea you use
the other ideas as your [Link] you cluster them [Link] we chose that as the champion
[Link], how will that happen that is called amalgamation and building up of an idea into the [Link], you
are building this idea into a concept [Link], this idea then you start working on this it is too open so I need to
close it [Link] and to close it further [Link], you know, please check out the areas which is not [Link]
those areas in and then you make a helmet which is all the [Link] look at this strap, there is no buckle
[Link] is the most innovative point: the strap is done using an [Link]?So here we have concept A
and the concept A is personifying [Link]?But it is a full [Link] is got all the features which are built
in.
So look at the Ease of Storage cluster [Link] these other ideas, you know, turning idea, the folding
idea, the Greek helmet [Link] this, the students somehow selected , you know; the receding
[Link] these two and he did not take one idea [Link] said that I would like to make it very
slim so he started with this which is partof the receding [Link] choose that as a champion and then took it
forward from [Link], how did the ideas were developed by using other ideas putting together and then
cameup with this where you press and you push the both cells inside and it becomes [Link] is the
Ease of Storage [Link] then, comes the Ease of Use [Link] the [Link] ideas, those ideas,
all put together and finally this was taken as a [Link] idea was taken as a champion because this has
with, you just have to wear it asa cap and push it [Link]?It was much more easy to wear so that was
considered as the main [Link] this further developed because the net is too [Link] were a lot of [Link]
won’t, you know, it won’t be acceptable as a [Link] those gaps were reduced and here you can see how
the net is becoming smaller and helmetcells are becoming larger, but still that whole idea is going [Link]
finally you can see the concept building into a Concept C which is the use of Easeof [Link] you have 3
[Link] competition between the Concepts is a very, very critical thing and from these threeconcepts now
we need to find out which one will be used for the current product [Link] product brief was very, very
[Link] would have encouragement of [Link] should have, you know, basically good storage and you
should have good [Link], all the three can have, all the three have three different
[Link]?First one is very difficult to store, it is still [Link] this one it is easy to [Link] is
ventilatable [Link] one is easy to store, it is ventillatable and easy to [Link], automatically the last one got
selected as the concept to go [Link] then we went to experts and asked them.‘What do you think about
this helmet?’They said ‘It’s horrible’.Who would want to wear a helmet which is broken from the [Link]'t
it an interesting perception?And this was the first reaction from the scientists and the engineers that it is like a
[Link] are designers should have the perception to make it look strong and not [Link] then
then, you know, Dr. Dinesh Mohan, again a professor, said ‘This is not goingto [Link] least make it two parts
receding then the, you know, we reworked the whole [Link] it two part [Link] that gap is also
hidden and it only collapses when you need to store and you do not, youknow, see the, you know, break very
clearly and different sketches were [Link] this is how the first conception came up about what the helmet
should look like.(Student Professor Conversation Begins: 03:04) Student 1: Sir, so does the break, like,
structuralintegrity, like, in a collision?Sir: Very good question!So just tell me, will the break compromise on the
structural integrity of saving a person’shead?Student 2: Breaks (in the helmet) will like it will observe more
[Link]: It will absorb more shock because you are getting it closer to your [Link] snug fit helmet is the
best helmet for saving your [Link] when the, when the hit happens it does not happen, something hitting you
all aroundyou [Link] it?Whichever side you hit, it gets closer and the fitting is also much better and you
getmuch better, much better [Link] that is very counter [Link]?So you have a much bigger task
of convincing [Link] it’s better than the other one and you should do, you should do evaluation bydoing
testing [Link] here we have one of our Mandar’s friend, wearing the helmet and showing, you know,how the
helmet works and this is called the first working [Link] rig will not be aesthetically [Link] will be built
by using existing helmet [Link] he took a large, he took three large helmets, chopped them and created a
helmet which [Link]?He does not have the, yoo know, and then showed us how the thing [Link]
used the same buckle, he did not even use the elastic [Link] is supposed to be [Link]?That is just a
[Link] is not a [Link] you use a mock up what will happen?It will not work but I can wear (it).It will not
collapse, but I can show.I will show you a mock up [Link] is a mock [Link] it is full, this is the helmet
when it is collapsed, this is the [Link] does not work and the volume becomes nearly reduced by two third,
one third, [Link] your mockups, this is a scaled mock [Link] can have a full scale mockup which I have
some in the [Link] actually have an Innovation [Link] the student finished this project we wanted to
carry this project forward, andwe took it up with the Shenoy Innovation Studio and we started working on this
by now experienceddesigners experienced engineers to take this [Link] the student does their juries
during their final presentation they have to showone photo realistic [Link] is the actual shape of the
helmet, the form and [Link] show a working rig or a mockup [Link] scale mockup [Link] make
a very good photo realistic mockup also which is as close to the mass manufacturedproduct because nobody
should be able to change your design intent later [Link] we are back to the Innovation [Link], Innovation
Studio is a professional [Link]?It is, it is not a student body [Link] got experienced designers
with 4-5 years [Link] got engineers, we use a lot of consultants from outside to work with us whenever
we haveproblems, you know, any of the materials and manufacturing and [Link] I was telling you
one helmet does not fit all, so we said whom are we workingfor, So we came up with a persona: an office going
person that has a largest populationof people who are using two [Link] they have, you know, the
maximum problems and we chose that persona and this is thatpersona and then we found their daily routine,
the average distances they travel, the typeof vehicle they use, type of shoes they use, to get whole
demographic information aboutthis [Link] you are now clear about your segment of the [Link] with that
segment of the user comes the very important task of showcasing the featuresof your [Link] remember we
were telling that the helmet will have a very good strap, which is elasticin nature with no [Link] has a duck
detailed so that the breeze will go [Link] each concept has to have all the features, the breeze goes in
and comes outand it keeps the head [Link] is an adjustable clamping system so that the elastic is not too
hard on your [Link], you adjust using the clamps which will take all the details of [Link] you have these
vents which will take care of all the ventilation [Link] you also have this very interesting [Link]
rubber is very important, right?Because?If it is raining, the water should not go in, but it should also collapse
and open [Link], the rubber detailing is very [Link] these are the initial sketches of the rubber detailing
when the, you know, when the helmetgoes in how will the rubber, sort of, becomes straight and helmet goes in
and when I pushit out how the rubber block the, you know, block the [Link], this is a very large working, and
we nearly spent 3 months working on this one [Link] is that tough when you have any nice concept it is easy
to say ‘Ok it will go in andcome out’, but when you have a rubber detail over there, how will the rubber
work?And the biggest challenge was the [Link] I have a straight cut of thermocol?I cannot because
that area will be [Link] there is an accident in that corner, the person will [Link] we need to have an overlap
and at the overlap the distance minimum 22 millimeter at allthe length of the [Link] once we did the
overlap the helmet was becoming very [Link], multiple problems and these are all the features which we, you
know, the helmet hadto [Link] then came all the product detailing aspects, how you detail out, how will you
revit, howthe shell will go in and out, the head dimensions, the control dimensions or how will the
[Link] are the other critical things?And these are generally, designer’s doodles are very
important for you to, you know, articulate,to come out of your thought [Link] this is called externalizing
your thought [Link] you sketch, for example when you sketch, you know, he is looking down, but when
yousketch you externalize your thought process and then when you resketch again you see thenumber of lines,
when you resketch again what happens, your internalizing and [Link] the doodles are a very
important creative journey in any design [Link], then we did all the detailing of how the thermocol shell
works, what type of shape,what type of plastic, you know, covering should come on it and how will the plastic
breakand lock into each [Link] this plastic shell has to lock into this plastic [Link]?So how will
that locking happen?Will it be very wobbling or [Link], one of you were saying it can be more
dangerous if it is not good enough, thatwill go and pierce your [Link] your helmet is not, if I have too many ribs
that can go and hurt the [Link]’re not, as per IS standards you can't have any, you know, projections
[Link], you have to be careful in all your detailing of how your detailing will be done, all these,you know,
sketches are all about detailing and taking the markup model, remember, wehad the designing solution, to the
next level of product [Link] then the biggest challenge was, you know, how will your top be buckled
to your bottom?See you have the top shell and that has to be buckled to the bottom [Link] aspect was, you
know, thought of multiple [Link] this shall be connected to this and then this should be connected to the
chin?That was one [Link] second option is the top one should be connected to the strap and this should
beconnected to the [Link] got it?Because the top should be tightest so this is connected to my chin, and this
fellow isjust hanging over there with the [Link] is one [Link] you have multiple options of thoughts is that,
this is a very very big challenge [Link] will you strap the helmet was also very, very challenging
[Link] also took a lot of [Link] how many years, took nearly 2 years to come up with, to sort out all
[Link] then came the final design [Link] can see how the thermocol has slots of this [Link], finally
what we decided, we are strapping from the top, right?We are strapping from the top through that thermocol
that is [Link] it is strapping from the bottom, the bottom is hanging there and hence , you know,buckle is
[Link] this is one stage, there are multiple stages of [Link] is one stage of [Link] after
this stage of development, like a, you know, Mr. Chari was our own aluminouwith a lot of experience in the
industry, you know, again, you know, went out and joinedanother company and then, we had another designer
join this called [Link] is now, you know, a [Link] from Indian Institute of Science (IISc), was sitting
continuouslywith this product for another one and a half [Link], remember I was telling you, every idea which
is creative and which is good for theuser can be detailed out to become a good [Link], that was a very
strong belief in me, I said I am not going to leave [Link] collapsing is going to solve my problem for both
ventilation and ease of storage andease of wearing, I am going to leave no stone unturned to see to it that this
is implementedfrom multiple levels, the materials used, the technology used in the manufacturing
[Link] will do everything to take it [Link] we then did the digital sculpting to get all the shapes
[Link] the very important aspects started [Link] when you see this helmet more on head, you
will not see the break because itis on the top right, so we had to take this cut inside, it is longer out, remember
theearlier helmet the cut was outside which you can see, so user perception was also a veryvery important
aspect for [Link] took that and then we, you know, got all the detailing done, we went back and did
thestrapping to the bottom [Link] it is strapping to this one and attached this to this one, that was a much
better idea,because when you pull this will automatically [Link] finally, you know, this is one of the stylized
versions which we couldn’t fabricatebecause the thermocol was not fitting in this also had to be [Link]
then, you know, we build the final option where with the steps coming in and with thatstep we used 3D printing
machine very creative, to vertically, to make both the shells ofthe [Link] with this we came up with the
option of the rib and the support structure and how,you know, for example, the volume of travel which will
happen inside and you also checkthe thermocol how it will go [Link] this is the final redesign option with the
visor of the total design which had allthe components of the collapsing, the ventilation and the visor is a very
important componentin every [Link] this is the final detailing of how your whole product was made with all
the clamp,buckles, rivets to put all the, all the parts [Link] from the CAD model we did, we did multiple
3D prints, you know, they would be an errorover here so we would print again join [Link], in this case is the
bottom shell and then we also have the gasket 3D [Link] the 3D printed gasket was not very,
you know, was not very [Link] became very tight when we assembled [Link] other components are very
difficult to 3D print because the hard components are [Link] flexible components are generally it is good
to mould [Link] are available in the market and we mold them because the molding costs is not
[Link] example, the tool cost for this part could be as high as 8 [Link] the gasket tool would be
just about 2000 [Link] it is good to, you know, do the gasket in real and do this in 3D print for your
trialpurposes and after that, you know, can, you know, take things to go [Link] then, you know, we came
up with the final version of how the collapsed state, what typeof volume it will occupy and you will also see that
it forms like a little small rectangularspace so it is easy to put in a [Link] it can go into a bag which is like a slot
or we can put on a rack, so multiple, youknow, advantages come [Link] we also want to have ventilation on the
top so if you lift the gasket ventilationports are available for air breathing [Link] these are the, you know, designs
which came up as the final design.I think, as of now in this design, we kept the visor fixed and it can be, you
know, itcan be actually swivelled [Link] actually, you know, if you remove the skewes it is [Link] if
somebody wants to buy a helmet without a visor they can buy [Link] it’s that kind of option that is currently
[Link] we thought when we did the survey, with the mock up models, everybody said that theyneeded it
with the [Link], did you consider space for spectacles?Sir: Yes, so that was a very important [Link]
here you can see the type of visor just coming out so [Link] if you see the model, enough room is there, the
visor comes out like [Link] this is the, you know, first prototype we made and we tested by [Link] at the
distance, pretty large the [Link] then what happened, then we integrated the little cap type design with the
[Link] this is the visor, you know, where, you know, the cap was [Link] is still under [Link]
the transparent 3D printed parts are very difficult, so we are not able to getin a single [Link] we
actually did this 3D printing and kept using a transparent gasket over here but itstill does not exactly mimic what
you [Link] we plan to mould this, you know, finally to get the visor [Link] another idea was can I just snap
on the visor and whenever I want I snap it on andI take it [Link], this also has this elastic for wearability so it is
easy to [Link] it has a special purpose to, you know, in the way you have to be trained to [Link] this is
very [Link] we were just wondering how, because if you wear it with and elastic it has to becoming from the
front, you [Link] we were trying to see how we can, you know, integrate that as a convenience of wear
and,you know, opening also has to happen like [Link] we were trying to block it and, you know, see to it that it
is always blocked over here,so when you are wearing you have to put your fingers in and [Link], it always
lock like this, you know, locked like [Link] that we are still working [Link] that this one, you know, collapses
inside and becomes like this [Link] the visor should have been there, the visor is there, the visor would open
up a littlebit and it also, because the visor is from here to here and now this has been, gone intothe visor and it
will open up and become this [Link] gasket is made of either EPDM or we can use Polyurethane and this is
also [Link] can use engineering plastics which is like polycarbonate, APS for motorcycle
racing,but if you are doing a regular to, you know, regular work, which is here, it can be, youknow, in a simple
blend of ABS, which is much [Link] these are all two, injection molded [Link] thermocol shells are
made of expanded polystyrene you [Link] here my challenge is, you remember, the earlier helmet had only 2
[Link] I have [Link] plastic dyes, two thermocol dyes, one visor dye and then the elastic [Link] I
must give you a good example over [Link] I tell you the example of the VIP Luggage Company, the VIP
luggage company, there ismy senior from IDC, who is the head of the, he is the vice president now, and he is
basedin Hong Kong to source all the components, because if you are not, if you are in theworld market in
luggage, you must have the components of ecosystem at level which iscommon in the [Link] zippers, the
plastic trims, the luggage or the polycarbonate shells, it has to beat that [Link] is a very important
understanding for us that to innovate, you also have an ecosystemaround you which will work very effectively to
take this forward.