Meet the Team: Greg Dussek, SST Design Engineer

by Karen Gait 14. November 2013 10:14

About Me
My name is Greg Dussek and I’ve been working as a Design Engineer at SST for just over 2 years since graduating from Bournemouth University with a first class degree in Product Design.   

Likes:

  • Motorbikes
  • Formula 1
  • MotoGP
  • Nights out with friends
  • Drum and Bass music
  • Cinema
  • Italian food

Dislikes:

  • Miranda Hart
  • Dumplings
  • Rainy days (can’t go fast on the bike!)

Thin Client SV510TF Design
Detailed below is an overview of my latest project and how I managed to fulfil the design brief and meet the cost expectations of the Sales Department.

The project brief was to design a TEMPEST Level A Thin Client using the HP510 OEM with the main objective being to keep the unit as small and good looking as possible. My utilisation of right angled connectors and small back shells meant that I was able to keep the final size not much bigger than the OEM donor unit. A risk when striving to minimise the product size is that assembly may prove impossible. I found that the best way to ascertain if production grade assembly would be possible was by using the triad point on parts in Solid Works and manuvering them into position as they would be done on the shop floor. Once all components are mated in position the Interference Validation test is a useful tool which highlights any parts which are touching or overlapping.

We are always trying to produce the most attractive products possible but I was also mindful of the cost associated with doing so. Often in our line of work aesthetics very much come second to function but on this occasion the SV510TF Thin Client was a great opportunity to design a stylish yet cost effective product. By adding an oversize radius on the top front of the box I was able to give it a more interesting form – but still maintaining a simple stylish look.

Adding this feature did increase the manufacturing cost, however by working with our supplier I was able to reduce costs in other areas to compensate. The welds were moved inboard to make it easier and quicker to manufacture and the silk screen was merged onto one screen to halve the cost.

In the design of TEMPEST products cooling is paramount. A wave guide beyond cut off strategy is adopted with our hole sizes/position relative to each other to allow for cooling. I then shaped these holes on the top and front faces to arrow like shapes pointing centrally down the unit giving a symmetric effect. These “arrow” shapes also point towards the user interaction with the product, mainly the power button and USB ports.

The entire unit is made from 3 sheet metal parts and one simple machining. Reducing component quantities is a great way to reduce build time and save money. Where ever possible larger, heavier items were kept at the bottom of the unit (PSU, fibre optic transiver, IEC) to try and make the unit more stable. As a further option I designed a simple stand, this is unobtrusive to the design but provides even better stability.

All in all it’s a nice clean simple product. It looks brilliant and does the job required of it. The SV510TF is now CFTCS certified to TEMPEST level A and available through www.sst.ws with a variety of options.

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