As Product Design-Compressed

Power Plug
Yeung Shing Cheong Candidate No:1079 Centre No: 19239 St Joseph’s College F522 Product Study Page: 1
Intended Purpose
What’s the product?
The product I have chosen to analysis is power plug.
What’s the need of this product?
Power plugs are devices that allow electrically
operated equipment to be connected to the primary alternating
current power supply in a building. Manufacturer’s Needs
When is the product likely to be used?
The product is most likely to be used anytime everyday, almost every
electrical appliance connected with a plug which needs to be plugged in What’s the manufacture cost?
a power socket. Power plugs have a really low manufacture cost because it’s a mass production product.
How does the product work? To keep the cost low the design is really important, a good design can reduces material
An electric plug is connected to the wall and connected to three color cost and manufacture cost. For example if a product has really complex structure or
coded wires. The red/black wire represents live wire, the white wire is neutral expensive material which will increase the manufacture cost.
wire while the green wire is for the earth wire. Appliances are connected to
What kind of material does the product made of?
its outlet. The plug will allow the electricity to pass from the electrical wiring The electric plug is made of thermo setting plastic, It’s permanently stiff and solid but it
to the appliance when needed. can’t be successfully remoulded after their initial heat-forming.
Injection Moulding
Who would use the product?
Power plugs are used all over the world, every school, office, How does the product been manufactured?
The electric plugs are manufactured by compression moulding and injection moulding.
building and house need Plugs and power sockets for power supply.
The conductor pins are often made from extruded brass section that is cut to off to size.
Eventually joined all the components together through assembly line.
Consumer Needs
To satisfy the user needs, the product must be:

-It needs to be easy to use(easy to be plugged in a power socket/ to
be plugged with a electric plug). Is this product safe?
-It needs to be safe to use, (prevent from getting electric shock). The electric plug is approved by BSI. The BSI
Kite mark is a conformity certification trade
-It need to be at a low price because this is a singular functional mark owned by BSI and was originally only
product used in the UK, but it is now recognized
throughout the world, it is one of the most recognized symbols of quality and safety and
-It must be approved by either CE or BSI which offers true value to offers true value to consumers, businesses and procurement practices.
consumers. FUSED
CE marking
BSI certification logo
Ergonomics
The design of the plug
Function
needs to be ergonomics. It
The power sockets and plug must allow electrically
need to have a nice grip
operated equipment to be connected to the
at the side which allow user User primary alternating current power supply in a
to use two fingers to plug in The plug should be approved by CE or BSI building. That allow electricity pass through
or pull out from the power which is guarantee to users. It should be appliances. Such as television, lights, computer,
socket. easy for user to use. washing machine…
Neutral Earth
Safety device
Live
It’s important for the product that is
high quality and safe for user. The
Fuse
product must be approved by the Aesthetics
appropriate agencies and the It should have a simple shape not necessary to
standards for the countries that it will have really outstanding design because it’s a
be sold in. For example: BSI kite mark mass production product. Every buildings, houses
or the CE. or school need pocket sockets and appliances
need electric plugs even they don’t have a
attractive design.
On-off switches Cable Size and Weight

clamp The plug should be light and handy. It
Safety should have a appropriate size which
The plug must be approved by BSI which is a can allow users to unplug and plug.
symbols of quality and safety. It need to have a The power socket should be big enough
standard fuse in the circuit. A fuse interrupts to plug in several electric plugs.
excessive current so that further damage by
overheating or fire is prevented. The plug case
Product Life and Maintenance
should made of plastic which is a insulator so
Power sockets and plugs should have a long product
that user won’t get electric shock.
life people don’t often need to replace their sockets or
plugs because they are durable and can withstand
high temperature. Plugs must be fused which can
avoid damages from short circuit. If short circuit
occurred the fuse should be able to replace and
power socket and plug still can be reused.
Environment Sustainability After the product life
This product must be suitable for use indoor in User must be able to sustainably dispose of the product. of a plug it’s not easy
buildings, houses, school... It must be able to It’s also important for the designer to design a product to be recycled.
withstand high temperature because it might which can be easily recycled for example, the plastic
produces heat while using it. The power plug case and brass conductor pins should be able to
socket should have screw holes so that it disassembly and recycle separately after it reached the
can be screwed on walls. end of the product life.
CATEGORY ANALYSIS
üThe electric plug has three conductor pins which can be perfectly plugged in a power socket.
üAt the bottom it has two screws which allow users to connect the plug to any electrical products or change the fuse.
üThe power socket has a on-off switch which allow user to switch off the appliances without unplugging the electric plug.
Function üIt has a safety device within the power socket which can stop users stuck their finger in the holes which can causes electric shock.
Some of the electric plugs haven't got nice grip at the side which make it really hard for users to unplug it especially old people or children.
The cable comes out at the bottom of the plug it might causes problem for instance, if you plugged a hair drier in a power socket which
located really close to the work surface the cable might over bend or even damage while using the hair drier at a certain height.
üThermosetting plastics are synthetic materials which strengthen on heating.

üAfter their initial heat-forming they cannot be reformed.
Materials Thermosetting plastics are really hard to recycle, but nowadays there are methods of crushing the objects into a fine powder form for use as
fillers in reinforced thermo sets.
They cannot go back to their original form after their initial heat-forming. They will burn when heated after the initial moulding.
Some of the thermosetting plastic are brittle they break after a few drops or impacts.
üManufacture aboard such as China which can keep down the manufacture cost due to the labour force is paid less, therefore maximising
profit and lowering price.
Manufacturing üOnce every things are set up the compression moulding machine can produce large quantity and quality of plugs in a short.
period.
The set up of compression moulding is really expensive such as the machines and moulds...
If there are any scratches on the mould the compression moulding machine will produce bad quality plugs which might need to be recycled.
üNice grip at the side of the plug which increases the friction allow users to plug or unplug.
üThe size of the plug is suitable for different age user s to use.
Ergonomics
üIt’s easy for user to figure out how to use a plug correctly even they have never been told how to do it.
There are some kind of plugs which are not easy to be unplugged because it has a smooth edge which reduces the frictional force.
üIt has a simple shape and looks to keep the production cost as low as possible.
Aesthetics üIt has a matches colour and style with a power socket.
Plugs in the market look mostly the same; cable come out from the bottom, black or white colour.
üIt has a really low production cost because it has a high volume production.
Cost üIt is affordable for everyone.
Safety gate closed Unplug Plugged Fuse provide

stopping object to Brass Pin Live Pin over current
be inserted. protection.
Earth Pin
Spring Safety gate is
Allows safety open which
Neutral Pin
allows it to be Plug casing
gate open
and shut. plugged
Power Socket (Internal) Electric Plug
PRODUCT FUNCTION MATERIALS MANUFACTURING ERGONOMICS AESTHETICS COST
The Mu – The Folding üPrimary function to supply
Plug electricity for electrical devices üThe case of the plug It is quite hard to be üIt looks nice with it’s
such as all usb smart phones, MP3 normally are made manufactured because It hasn’t got impact shape and It costs £25. It
https://www.themu.co.uk players and Kindles. out of thermal setting it has a lot of separate enough friction at the white colour. is really
üCan be folded to compact plastic and the components which can side which make it expensive
shape which is convenient to conductor pins are increase the hard to be compare with
users to carry it around. made of alloy. This manufacture cost. unplugged.
üIt has a compact the traditional
Need to open wings > Twist Pivot product has a low shape when not plug.
> Plug in. It’s not easy to use material cost. using. It is the
compare with traditional plugs thinnest 3 pin plug in
It can only be used in the United the world.
Kingdom, Ireland, Hong Kong,
Singapore, and Malaysia.
Universal Plug üPrimary function to be used The case of the plug It has a lot of
http://www.world- in different countries, it’s a normally are made üIt has a thick body conductor pins üIt costs £7-10
import.com/Universal_Multi_purpose_plug
_adapter_for_World_Wide_Use_WSS883U.h universal adaptor suitable for out of thermal setting It has a complex and large contact sticking out from the is the
tm
travellers. plastic and the internal design and area to grip on bottom which isn’t cheapest
conductor pins are more material therefore it could be really attractive. compare with
made of alloy. The unplugged easily.
üSuitable for use in over 150 universal plug needs
required for the apple
countries more material manufacturing. üWhite and orange plug and the
because it has a lot colour which gives folding plug.
It is bulky, not easy to carry it more pins and it has a modern looking.
around. larger shape.
Apple Power Plug üPrimary function to supply power
http://store.apple.com/uk/product/MD81 for Apple devices such as iPhones, It is really hard to üIt has a compact
2B/B/apple-usb-power-adapter?fnode=3c
iPods, iPad minis... üThe case of the plug I am not sure about pull it out from a shape compare to It costs £15 it is
are made out of the manufacturing power socket the universal plug. quite expensive
üThis power adapter offers fast, thermal setting plastic process of apple plugs sometimes compare with
efficient charging at home, in the and the conductor the traditional
office, or on the go. It works with pins are made of alloy.
because it’s a bit because it hasn’t üIt has a simple and plug.
any iPhone and all iPod models This product has a low different from the got a nice contact unique design which
with a dock or iPhone cable. material cost and it traditional plug. area to pull. matches with
can be recycled. apple’s products.
It can only be used in the United
Kingdom, Ireland, Hong Kong,
Singapore, and Malaysia.
Summary
For my plug it have to conduct electricity from the power socket to appliances. It needs to be made in a plastic which can withstand high
temperature and rigid. It needs to be safe so it must be fused to prevent over load. It should be easy for users(10-80yrs) to use. Should avoid
making my plug too complicated to use or bulky, it should have a compact shape and light weight. Try to avoid designing a plug which
contains lots of part which will increase the manufacturing cost and harder to be recycled. My plug should have a nice grip which allow users
to unplug easily. Lastly, the cost shouldn’t be higher than £20, should keep it at an affordable price.
As product designers and maker it’s important to consider
the social, economic and environmental, it’s not just about
making profit as big as possible. Social, economic and
environmental are usually interlinked and don’t easily fit
into one separate category.
Environmental
Life-Cycle Assessment (LCA) is a technique to assess environmental impacts associated with all the stages of a product's life
from-cradle-to-grave (i.e., from raw material extraction through materials processing, manufacture, distribution, use, repair
and maintenance, and disposal or recycling).
Thermosetting plastics are synthetic materials which strengthen on heating, but cannot go back to their original form after
their initial heat-forming. They will burn when heated after the initial moulding which make it really hard to recycle after it’s
product life. Products that are really hard to be recycled usually have a serious impact to the environment especially if it’s a
high volume product.
A Product Carbon Footprint (PCF) is a means for measuring, managing and communicating greenhouse gas (GHG) emissions
related to goods and services. A carbon footprint is based on a life cycle assessment (LCA) but focuses on a single issue
which is global warming. An increasing number of companies quantify the carbon footprint of their products. Companies
make these efforts for multiple reasons: enhancing market reputation, engaging with suppliers, clients and other
stakeholders, and setting a first step towards a more comprehensive environmental footprint.
Transportation of products is directly related to Product Carbon Footprint.
Modes of transport
Road - Road transport is cheap, convenient and one of the most flexible modes of transport, but it's not as eco-friendly as other methods.
Rail - Rail transport is speedy, environmentally friendly and not always subject to congestion or delays. However, it is inflexible and can be very expensive.
Air - Airfreight is, without a doubt, the fastest way to transport your products across long distances but it's expensive and not very eco-friendly.
Sea - Compared to airfreight, shipping your products by sea is relatively cheap, particularly if you are sending large volumes. It's slow, though, and fairly inflexible
Courier - Couriers are fast, reliable and very secure, but can be costly. Couriers are usually only cost-effective over short distances
Economic
How would the product impact on employment opportunities? Will there be more or fewer jobs as a result?
Electric plugs is a high demand product because almost every electric device connect to a plug which mean every single electric device need a plug with it
before selling it to customers. To provide large amount of plugs a lot of workers and factories are required. Most of the plug are manufactured in china which will
increase the employment opportunities and the economy in China
Social
14
Social responsibility means ensuring that our own and other people’s quality of life and human right are not
compromised to fulfil our expectations and demands.
Does the product improve the quality of life for its users?
It doesn’t directly improve the quality of the life for users, what it does is to connect appliances and power socket
which allows users to watch TV, charge their gadgets, light up bulbs….
Is this product appropriate for the society and culture in which it will be used?
It is totally appropriate for the society and culture to be used.
Does the making of the product have a positive or negative impact on the quality of life for some people, including
those living elsewhere in the world, sometimes in poverty?
Most of the electric plugs are manufactured in factories in China to keep the cost as low as possible. It does have
impact on the quality of life for people in China because of the pollution from factories we should aware of the
situation because it’s not fair for those people live in China especially the people that live near factories.
Low cost
To solve this problem
The common problems that travellers the plug should be Design Brief
are having is taking their chargers It should have a improve in the way
compacted shape, brings users unplug it for
and plugs. Plugs should be improve
in the way it looks and the size, such
users convenience example users can I have analysed my product, and have identified
specially people that some problems. They were:
as make it foldable or thinner. twist or press to unplug
often travel .
that will be easier for -The plastic case of the plug is rigid but brittle.
women and elders.
Light weight -Not easy for women, children and elders to
unplug.
Nice grip Twist to unplug
-Cable over bended and damaged if the plug
located really close the working surface.
It should be made of a
material which has a low cost, -The direction of the cable coming out from the
rigid, can withstand high It needs to be easy for plug should be adjustable to suit different
temperature and can be users to use for
recycled. Possible example some elders working place and appliance.
improvement or women might find it
to my product -Thermosetting plastic is not easy to be recycled.
not easy to unplug.
Recyclable
-The size of a plug is quite important specially for
The cable usually come out Adjustable travellers. Plug should have a compact shape so
from the bottom of the plug it that it would be easier to take around.
might cause damage to the The only way to solve this problem is to
cable if the plug is located relocate the cable. I would make it
really close to the working adjustable so that the direction of the -The improvement should help children, women,
surface. cable can be adjusted depends on the elders or weak people to unplug the electric
situation. plug from the power socket.
Modern design
-I will try to improve the aesthetics of the product
Design Specification because I think the traditional plug doesn’t look
Function: nice.
F1 The product must work with the traditional power socket which is three pinned this will still keep its Cost:
main function and allow for continuity . The price of my product needs to be affordable shouldn’t be too expensive.
F2 The cable should come out at the middle instead of the bottom which would help in rectifying the It could be slightly expensive than the traditional plug because of it function
issue identified above. and there isn’t any plug in the market does the same function therefore the
F3 The cable from the plug should be able to adjustable to different angle when needed. price range should be about £5-15.
Should have nice friction at the side to make it easier to unplug.
Aesthetics: Quality:
A1 As the existing product doesn’t look nice, personally I think the aesthetics of the product are very The quality of my product needs to be high standard because it’s directly
important therefore, the style of traditional plug need to be improved. related to the safety of the product. Bad quality plug could lead to circuit
Ergonomics: over load or even set up a fire which is a threaten to users. The quality of the
E1 The product should be easy to pull out from a power socket. It needs a nice contact area for users tomaterial needs to be good enough to withstand high temperature and
pull. impact resistance. The product should be approved by BSI which is one of
E2 The product should be easy to use for all people with different sized hands. the most recognised symbols of quality and safety and offers true value to
Materials: consumers, businesses and procurement practices.
M1 The product should use the smallest achievable amount of material. This is cheaper and easier to
manufacture, and is more environmentally friendly. User:
M2 The materials used in the product must be resistant to high temperatures. Otherwise the product The quality and function is really important for user because users tend
may melt or accident may occur. to buy product which has good function and quality. Therefore my
Environment:
product should function well and reach high standard of quality.
E1 It shouldn’t produce any pollution or damage to the environment. It must be recyclable.
1
4
3
Real time evaluation of initial ideas
I really like the idea 4! Sometimes I find it really I really like that idea but the big challenge
annoying to carry a 3 pin plug around while for me is the connection between the pins
travelling because it’s bulky but the flippable plug and cable which will be really complex to
can fold it to a compact shape which is a lot easier design therefore I wouldn’t choose that idea
to carry around it might even fit into my pocket. for my final product.
PERSON 1 MY RESPONSE
Idea 3 is really useful with that design
people won’t need to spend extra money I really like the idea 3 but because of the
on a plug extender which takes up a lot of safety issue I would not suggest to have a
space. But on the other hand I don’t think socket at the back of the plug. The sliding
it’s a safe product because it could lead cable idea is quite new and it would be
to circuit overload if too many plugs are useful therefore I will try to develop on the
being use at the same time. The second sliding function can try to work out the
feather of the plug is quite special I have internal design of it.
never seen a plug with a cable which can
slide along the side.
MY RESPONSE
PERSON 2
I think idea 1 and 2 are really useful in some
situation for example there are some awkward I think idea 1 and 2 is the best so far but I realise that
location for a power socket and a normal plug idea 2 is not possible because it has too many rest
just can’t plug into it which I find it really channels and the ball and socket won’t be able to
annoying. And the second issue is my iPhone make every single turn therefore I would reduce the
cable worn up because I charge my phone channel to 3 or 4. For idea 1 the shape is quite tricky
on the my desk every night and the end of the to make , there won’t be enough internal space for
cable constantly bending because the cable wiring therefore I am going to combine idea 1 and 2
came out from the bottom of the plug. I think and take it to further development.
idea 1 and 2 can solve this issue.
PERSON 3 MY RESPONSE
That a design of a grip with a special pattern which has a lot Pin slots allows pins to fold in when
Recessed slots Earth Pin more friction so that less force is required to unplug. not using so it’s more compact.
Neutral Pin Live Pin
Plug case Brass Pins

Semi-Transparent view
Internal design drawing That’s a improved embossed pattern which
Brass pin can be folded when it’s not
have lots more contact area between users
being used. It has a compact shape
finger and the side of the plug makes it
compare with traditional plug.
easier to be unplugged, so it’s ergonomics.
Final 3D Model
Grip from apple
plug has a smooth
side indent which
doesn’t provide
enough friction
therefore some
users find it quite
hard to unplug it.
Flippable Plug
3D modelling, testing
2D draft of the cable slide
The dimension needs to be very accurate so that all the
components can be join together and work properly. Step of 3d modelling (Cable Slide)
Cable slide
allows cable to
slide on the
channel.
Bottom case Upper case Cable Slide My sliding plug allow

cable to slide 360
degrees all around the
plug unlike the traditional
plug which has cable
Assembly held firmly at the bottom.
Final 3D Model
Internal design drawing

Sliding Plug
3D modelling, Sliding test
That shows how exactly my sliding
plug works, the internal design is
really complex compare with the
traditional plug. The contact ring
and cable slide allows electricity
from power socket pass through the
brass pin, conduction ring, contact
ring, cable and finally to appliances
even the cable is sliding around the
plug.
The conduction rings are connect with Neutral Cross-Sectional Model Live
Earth, Live Neutral Pins in the hollow tube Conduction Conduction
which located at the centre of the plug. Ring Ring
Live wire
The purpose of this connection design is entry hole
to allow electricity from the pins passes to
the conduction rings and to the wires Cable entry
Upper hole
which are attached to the contact ring,
Casing
the electricity still passes through the
cable while spinning. Neutral wire
Earth entry hole
Conduction Cable Slide
If I could improve the design even further I Ring
would make the shape of the sliding plug
more compact by redesigning the Earth wire
contact ring which takes up more than entry hole
Holes for cable securing screws half of the thickness of the whole plug.
(Live, Neutral and Earth wires ) Bottom
Lastly, I think the securing lugs need to be Casing securing lugs
Live, Neutral and Earth Prevent cable slide off the
thicker to ensure that the cable won’t be
Live Pin channel
wires entering holes physically put out while sliding. Neutral Pin Earth Pin
Ball & Socket Plug
idea 1&2
Problems with the traditional ball and socket
-The internal cables will snap when the ball
and socket is at a angle of 90 degrees.
-The cable hole isn’t big enough for Earth,
Live, Neutral cables to pass through. It
needs to be 4mm or bigger.
This is a joint design

Initial design(ball) which allow electric
cable to pass
through that joint
This is the 2d draft of the ball which shows the internal and it is ball and
and external dimension of the ball socket joint which
allows the cable to
swivel.
This is a special designed ball and

socket joint which won’t damage the
cable while swivelling. The maximum
working angle is no bigger than 90
degrees.
Ball & Socket Plug First Prototype

2D modelling, Testing
Images above show the process of producing a 3d
model on Pro-desktop. The accurate dimension of the
design is required to produce a 3d model which can
be tested on computer. It is not easy to create a 3d
model of my product need to spend hours and hours
on trying, failing, improving and finally produce a 3d
CAD model.
The problem I had while making the upper case on Pro-

desktop is the location of the securing lug, I spent a lot
of time of taking measurement and kept trying and
redoing and finally I managed to make it fit with the
bottom casing.
The second problem is the thickness of the plug casing

it needs to thicker otherwise I will break easily. I have
got some feedback from my teacher and he
suggested me to add some strengthening rips within
the plug to make it stronger.
To allow my product to be used with a original 3 pin power socket my plug needs to
follow the exact size and distance between each pin if it’s slightly different my plug won’t
be able to plug to a normal power socket therefore I need to do some research to find
out about the dimension of plug and socket before making my 3d model.
Purpose of engineering drawing
Engineering drawing is a graphical language that
communicates ideas and information from one mind to another.
It is the sole method of transferring information from design into
manufacture. Without engineering drawing of a product
manufacturer won’t be able to manufacture your product
therefore engineering drawing is really important and it needs to
shows all the feathers and dimension of the product in different
view or even cross sectional drawing or exploded drawing to
show the detail of the structure and components of the product.
Ball & Socket Plug
3D modelling, 3D Printed prototype, assembly and Testing
Real time evaluation of 3d printed prototype
Tester 1 mentioned a problem of dust

might collect on the surface of the cable
rest channel which it’s easy to clean. In
my opinion, a feather duster can get rid
of the dust on the plug easily or apply a
dust proof layer on the surface of the
plug but that will increase the cost of it.
MY RESPONSE
TESTER 1 It’s depends on the quality and

thickness of the cable if the ball
and socket plug connected to a
bad quality cable it might worn
out in a short period of time. It’s
a problem that I really should
concert about as it’s about the
safety of my product.
TESTER 2 MY RESPONSE
Final Version Strengthening
Final Version
Rips
Ball & Socket Plug
On my old version
plug, the plug
Upper Casing casing can be
Old Version
Side Indent deformed easily
Grip therefore, I
increases the wall
thickness from
1.5mm to 3mm and
added
strengthening rips
in-between pin
socket and
Bottom Casing securing lug to
make the plug
stronger.
Socket
Ball Cable
Upper Rest
Socket Casing
Channel
In the final improvement of my ball
and socket plug. I changed the
The thicken of the socket increases raised profile grip to an indent grip
from 0.75mm to 1mm.
which is easier for user to grab on.
The reason I replaced the raised
The reason I used white and grey colour for my profile grip with an indent grip is
final version plug it’s because most of the people because the pervious grip doesn’t
thinks that power plug shouldn’t be too colourful feel comfortable when unplugging Earth Pin
Fuse
Bottom
Securing Casing
therefore I changed the green socket to grey. that’s why I decided to use an
Strengthening
Lug Rips
indent grip for my plug. Fuse

Retaining
Earth Pin Strip
Live Pin
Evaluation Against Specification
I asked my three testing users to evaluate my product against my original specification, the results obtained will show me to what extent my ambitions have been achieved. This will also
show me any areas of my product that could, or would need to be improved. On a scale of 1 to 5, 1 is ‘the point is not met’, to 5, ‘the point is fully met’.
Category Point From Specification Tester 1 Tester 2 Tester 3
The product must work with the traditional power socket which is three pinned this will still keep its main function and
allow for continuity . 5 5 5
Function
The cable should come out at the middle instead of the bottom which would help in rectifying the issue identified
above. 5 4 5
The cable from the plug should be able to adjustable to different angle when needed.
Should have nice friction at the side to make it easier to unplug. 5 5 4
Aesthetics
As the existing product doesn’t look nice, personally I think the aesthetics of the product are very important therefore,
the style of traditional plug need to be improved. 5 5 4
The product should be easy to pull out from a power socket. It needs a nice contact area for users to pull.
4 5 3
Ergonomics
The product should be easy to use for all people with different sized hands.
5 5 5
The product should use the smallest achievable amount of material. This is cheaper and easier to manufacture, and is
more environmentally friendly. 4 3 4
Materials
The materials used in the product must be resistant to high temperatures. Otherwise the product may melt or
accident may occur. 4 4 5
It shouldn’t produce any pollution or damage to the environment.
5 4 5
Environment
The product must be able to be recycled after it’s product’s life.
4 3 3
The price of my product needs to be affordable shouldn’t be too expensive. It could be slightly expensive than the
traditional plug because of it function 3 4 4
Cost
Price range should be about £5-15
3 3 4
The quality of my product needs to be high standard because it’s directly related to the safety of the product. Bad
quality plug could lead to circuit over load or even set up a fire which is a threaten to users. 4 4 5
Quality
The quality of the material needs to be good enough to withstand high temperature and impact resistance. The
product should be approved by BSI which is one of the most recognised symbols of quality and safety and offers true 4 4 4
value to consumers, businesses and procurement practices.
Socket Socket
Modification If I could improve the ball and socket plug even further, I will improve the ball and socket part because Increased
sometimes the socket jams in the ball which could cause damage to the plug. My solution is to increase the thickness of the top bit thickness
of the ball to prevent the socket jam in it. I can’t prove that the solution is going to work because it’s really expensive to print out my
prototype to test it.
I would also add variety of colour for my ball and socket plug which allows user to choose a plug that matches with their gadgets or
appliances. i.e. a Macbook looks nice with a white plug, a black colour laptop looks nice with a black plug… Personally I would like BEFORE Ball AFTER Ball
to have a plug in green or blue colour which is not common to have in the market.

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Power Plug

To satisfy the user needs, the product must be:

On-off switches Cable Size and Weight

üThermosetting plastics are synthetic materials which strengthen on heating.

Safety gate closed Unplug Plugged Fuse provide

Neutral Pin Live Pin

Plug case Brass Pins

Bottom case Upper case Cable Slide My sliding plug allow

Internal design drawing

This is a joint design

This is a special designed ball and

Ball & Socket Plug First Prototype

The problem I had while making the upper case on Pro-

The second problem is the thickness of the plug casing

Tester 1 mentioned a problem of dust

TESTER 1 It’s depends on the quality and

Ball & Socket Plug

indent grip for my plug. Fuse

Category Point From Specification Tester 1 Tester 2 Tester 3

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