Student No. 242018 Scale — NTS Stellenbosch, South Africa

Industrial Product Designer · 3D Fabrication Specialist

Liam
Cloete.

Third-year Industrial Design student at The Open Window Institute, specialising in the full product development pipeline — from ideation and user research through CAD modelling, engineering documentation, and hands-on physical fabrication. Driven by functional minimalism, material honesty, and the conviction that the details no one notices are precisely the ones that make a product feel intentional.

Explore Portfolio Get in touch
Location
Stellenbosch, ZA
Phone
066 232 9706
Email
[email protected]
Status
BA Industrial Design, in progress
§01

Current Work — ID 300

CAD Scale — NTS

01 — Hackathon, boardgame system

Boiler Boom

A 2v1 asymmetric steampunk board game pairing tile-placement mechanics with a physical GM controller and a live digital dashboard. Card economy validated through Monte Carlo simulation before a single tile was cut.

Board is a split-panel laser-cut assembly driven by an Arduino GM rig — atomiser humidifier, WS2812B LED ring, rumble motor via L298N — physical feedback tied directly to in-game events.

Laser-cut split panel WS2812B / L298N In development
CAD Scale — NTS

02 — ID 300, STEM toy, ages 3–6

Colour Creature

A tactile CMY subtractive colour-mixing toy for early-years learning, built from PLEXIGLAS® acrylic paddles set in a Baltic Birch plywood frame. Children stack and overlap paddles to physically discover how cyan, magenta and yellow combine.

Backed by in-store market research across 54 competing STEM toys in Cape Town, developed to ISO 8124-1 toy safety compliance at a landed unit cost of R759.36.

Acrylic + Baltic Birch ISO 8124-1 R759.36 / unit

More Selected Work

Four full case studies documented across brief, challenge, process, launch and next steps.
§02

Project Case Studies — Full Year

01 — Brief 01 — Single-Board Mechanical Toy

Roto-Plane

Kinetic play object · Ages 6–10 · Workshop-fabricated toy

A single-sheet MDF flying toy with two independent moving assemblies, built to survive repeat handling and demonstrate mechanical motion at play scale.

Sneak peek — key specs

  • 9mm MDF monomaterial
  • 2 moving assemblies
  • 5+ components
  • Dowel joinery

Stage 02

Design Challenge

Toys manufactured from one board stock rarely deliver moving mechanisms without fasteners or secondary materials. The design challenge required a functional flying toy cut from a single 9mm MDF board, carrying a minimum of two moving parts and five combined components, while remaining durable under repeated child handling.

Stage 03

Design Process

Research insights

  • Board-derived toys fail most often at unreinforced pivot points.
  • Play value increases when two mechanisms can be operated independently.
  • Single-material builds simplify sanding, finishing and cost control.

Core features

  • Ball-bearing rotating wing assembly with free spin
  • Toothpick-pivot articulating flaps, independently movable
  • Dowel-reinforced fuselage joinery, glue-only fixing

Refined sketches

  • Nested cut layout maximising yield from one board
  • Pivot studies comparing dowel, bearing and press-fit options

CAD & visual design

  • 2D nesting layout for band-saw cutting sequence
  • Sectional pivot detail confirming bearing seat depth

Technical manufacturing data

Material
9mm MDF, single board
Processes
Band saw · Drill press · Hand sanding
Fixing
PVA wood glue + dowel joinery
Tolerance
±0.5 mm on bearing seat
Finish
Sanding sealer, three-coat

Fabrication process

  • Profile cutting on band saw from nested layout
  • Drill-press boring for dowel and bearing seats
  • Progressive sanding 120 → 240 grit before sealing

Final product

  • Sturdy airframe with clean sealed surfaces
  • Wings rotate freely; flaps articulate without binding

Stage 04

Product Launch

Promotional material

  • Workshop-context product photography
  • Mechanism breakdown poster

Video & media

Mechanism demo

Short-form clip — wing spin and flap travel

Proof of user interaction

  • Peer play-testing confirmed durability across repeated throws

Unit economics

Material cost
Single 9mm MDF board
Scrap rate
Low — nested cut layout

Stage 05

Conclusion & Next Steps

How the challenge is answered

  • Two independent mechanisms satisfied from one board stock
  • Component count exceeded the five-part minimum without fasteners

Key technical takeaways

  • Bearing seats in MDF require reinforcement to hold tolerance
  • Nesting decisions drive both cost and structural grain direction

Future development

  • Convert pivots to moulded inserts for injection-moulded scale-up
  • Add a launch mechanism to extend play duration

02 — Brief 02 — Sheet Metal System

GardenTower (DaLi)

Modular indoor gardening · Small-footprint student housing

A ceiling-mounted modular growing system in 2mm mild steel that reclaims unused vertical volume in compact living areas.

Sneak peek — key specs

  • 2mm mild steel
  • Laser · Bend · Weld
  • R1,500 / unit
  • 20mm edge radius

Stage 02

Design Challenge

Compact student accommodation offers minimal floor area for indoor cultivation while vertical and ceiling volume remains unused. The design challenge required a space-efficient, modular growing system that mounts overhead, holds load safely, and is manufacturable through standard sheet-metal processes.

Stage 03

Design Process

Research insights

  • Floor-standing planters compete directly with scarce circulation space.
  • Ceiling mounting shifts load away from furniture and walls.
  • Modularity allows the system to scale with the grower, not the room.

Core features

  • Stacked modular trays on a common suspension spine
  • 20mm edge radius on all user-contact geometry
  • Flat-pack sheet profiles for efficient nesting

Refined sketches

  • Suspension and load-path studies
  • Tray profile iterations balancing volume against bend complexity

CAD & visual design

  • SolidWorks parametric assembly with sheet-metal flat patterns
  • SolidWorks Visualize renders for in-situ presentation
  • GA and exploded drawings for full documentation set

Technical manufacturing data

Material
2mm mild steel
Processes
Laser cutting · Press-brake bending · MIG welding
Bend radius
Matched to 2mm stock, inside radius 2mm
Safety
20mm radius on exposed edges
Finish
Powder coat, DaLi brand palette

Fabrication process

  • Laser cutting of nested flat patterns
  • Press-brake forming to bend sequence
  • Weld assembly of spine and tray brackets

Final product

  • Hi-fi ceiling-mounted modular tower
  • Complete DaLi brand identity, Dieter Rams influenced

Stage 04

Product Launch

Promotional material

  • Market posters
  • In-situ photography in student housing

Video & media

Render walkthrough

SolidWorks Visualize turntable sequence

Proof of user interaction

  • Presented in-situ to student residents for placement feedback

Unit economics

Target unit cost
R1,500 validated
Market
Student and small-apartment growers

Stage 05

Conclusion & Next Steps

How the challenge is answered

  • Floor area preserved by relocating cultivation overhead
  • Modularity lets a single spine serve varied grow volumes

Key technical takeaways

  • Bend allowance discipline is decisive in sheet-metal cost control
  • Brand identity and product geometry benefit from shared language

Future development

  • Integrate drip irrigation and a passive drainage path
  • Prototype an anodised aluminium variant to reduce hanging mass

03 — Brief 03 — Flatpack Furniture

Flatpack Vinyl Holder

Tool-free flatpack furniture · Vinyl collectors

A CNC-routed Baltic Birch storage unit for records, turntable and amplifier that assembles by friction fit alone — no glue, no fasteners.

Sneak peek — key specs

  • 12mm Baltic Birch
  • CNC routed
  • Zero fasteners
  • <20% wastage

Stage 02

Design Challenge

Vinyl collections, turntables and amplifiers are typically split across mismatched furniture that cannot be relocated without disassembly tools. The design challenge required a mobile, dedicated storage unit assembling entirely through friction-fit joinery, cut from a single sheet with material wastage held under 20%.

Stage 03

Design Process

Research insights

  • A 25-response collector survey placed mobility above capacity.
  • Fastener-based flatpack loses joint integrity across repeat assembly cycles.
  • Equipment and records are usually stored apart, forcing double handling.

Core features

  • Interlocking friction-fit joints, tool-free assembly
  • Dedicated bays for records, turntable and amplifier
  • Single-sheet nested cut layout

Refined sketches

  • Joint geometry iterations tested for interference fit
  • Bay proportioning against standard 12-inch sleeve dimensions

CAD & visual design

  • Parametric joint model driven by material thickness
  • Nesting layout confirming sub-20% wastage

Technical manufacturing data

Material
12mm Baltic Birch plywood
Process
CNC routing, single sheet
Joinery
Friction-fit interlock, no adhesive or fasteners
Fit tolerance
−0.2 mm interference on slot width
Wastage
Under 20% of sheet area

Fabrication process

  • CNC profile and slot routing with climb-cut finishing pass
  • Edge sanding and dry-fit verification of every joint
  • Full assembly and disassembly cycle testing

Final product

  • Self-supporting functional prototype
  • Six-page assembly manual issued with the unit

Stage 04

Product Launch

Promotional material

  • Six-page illustrated assembly manual
  • Lifestyle set photography

Video & media

Assembly sequence

Timed tool-free build documentation

Proof of user interaction

  • 25-response user survey informed bay sizing and mobility priorities

Unit economics

Unit cost
R2,990
Sheet yield
One unit per sheet, <20% waste

Stage 05

Conclusion & Next Steps

How the challenge is answered

  • Tool-free assembly achieved without adhesive or hardware
  • Records and equipment consolidated into one relocatable unit

Key technical takeaways

  • Interference fit in plywood must account for ply thickness variance
  • Nesting efficiency is a design constraint, not a post-process

Future development

  • Add a cable management channel behind the amplifier bay
  • Test bamboo ply for lower embodied impact at equal stiffness

04 — Brief 04 — Rotational Moulding · ARMSA 2025

SphericonRoller

Gross-motor play equipment · Ages 3–5

A rotationally moulded LLDPE sphericon that converts a push into multi-axis motion, developing vestibular and gross motor control.

Sneak peek — key specs

  • LLDPE rotomould
  • SANS 50071
  • 1:6 FDM prototype
  • R70–90 material

Stage 02

Design Challenge

Conventional ride-on and push toys deliver single-axis motion, providing limited vestibular and gross-motor stimulation for children aged three to five. The design challenge required a rotationally moulded play object generating multi-axis movement while meeting national playground-equipment safety standards.

Stage 03

Design Process

Research insights

  • Multi-axis motion drives balance development more than linear rolling.
  • Sphericon geometry converts a straight push into an oscillating path.
  • Over-roll risk is the primary hazard in free-rolling play objects.

Core features

  • Sphericon form producing continuous multi-axis roll
  • Integrated over-roll preventatives
  • Ergonomic handles scaled to a 3–5 year grip

Refined sketches

  • Sphericon development studies and roll-path mapping
  • Handle placement iterations against child anthropometrics

CAD & visual design

  • Surfaced sphericon geometry with uniform wall thickness
  • 1:6 scale model prepared for FDM output

Technical manufacturing data

Material
LLDPE
Process
Rotational moulding
Standards
SANS 50071-1 · SANS 50071-3
Wall thickness
Uniform, rotomould-appropriate
Prototype
1:6 FDM, professional paint finish

Fabrication process

  • FDM printing of 1:6 scale prototype
  • Filling, priming and professional spray finish
  • Roll-path verification on the scaled model

Final product

  • Presentation-grade 1:6 prototype
  • Complete ARMSA 2025 competition submission

Stage 04

Product Launch

Promotional material

  • ARMSA 2025 competition boards
  • Product and context photography

Video & media

Roll test

Scaled model motion capture clip

Proof of user interaction

  • Roll behaviour demonstrated and observed at scale-model review

Unit economics

Material cost
R70 – R90 per unit
Wholesale
R210 – R350 per unit

Stage 05

Conclusion & Next Steps

How the challenge is answered

  • Multi-axis motion delivered from a single passive geometry
  • Safety standards addressed through radius, mass and over-roll control

Key technical takeaways

  • Uniform wall thickness governs both rotomould quality and cycle time
  • Scaled prototypes still validate roll dynamics when mass is corrected

Future development

  • Full-scale rotomould tooling trial
  • Structured play testing with a 3–5 year cohort
§04

Experience

Oct 2025 – Present

Student Council — Campus Pulse Coordinator

Open Window · Part-time · Stellenbosch

  • Gathered, analysed, and presented data on student engagement and campus culture to guide campus initiatives and support student-centred decision making.
  • Designed and ran campus-wide surveys and feedback polls after major events, turning results into reports and dashboards presented at council planning meetings.
  • Worked with the marketing team to translate feedback data into infographics and visual highlights, supporting orientation week, activations, open days, and graduation.

2023 – 2026

Prototype Fabrication Consultant & Lead Technician

Freelance · Open Window Institute, Stellenbosch

  • Consulted on and fabricated 3D printed prototypes for 2nd & 3rd year design students, managing print settings, material selection, tolerancing, and quality control.
  • Optimised SolidWorks and Fusion 360 models for reliable FDM output; troubleshot hardware and geometry issues to meet tight academic deadlines.
  • Operated as a one-person studio: client brief → CAD validation → print execution → post-processing delivery.

2024 – 2026

Creative Computing — Physical Computing & Embedded Systems

The Open Window Institute · Academic + Applied

  • Programmed microcontrollers in C++ (Arduino IDE) to build interactive, sensor-driven physical prototypes — combining design intent with functional electronics.
  • Integrated MPU6050 gyroscope/accelerometer with WS2812 RGB LED arrays to engineer a motion-activated directional wearable safety system (Smart Helmet).
  • Developed custom keyboard accessories and 3D printed keycaps (Cherry MX profiles, PLA) — applying industrial design principles to everyday tactile objects.

2026

Media Team Coordinator

Brand Stellies · Stellenbosch, South Africa

  • Conceptualised and produced visual communication assets for internal brand interviews and activations.
  • Coordinated media production workflows, ensuring narrative cohesion and on-deadline delivery across multiple concurrent projects.
§05

Technical Competency Matrix

A — CAD / Digital

  • SolidWorks (Advanced)
  • Fusion 360
  • Keyshot Studio
  • Photoshop
  • Adobe Illustrator
  • Parametric Modelling
  • Engineering Drawings
  • Exploded View / GA
  • Miro / Google Slides

B — Fabrication

  • FDM 3D Printing (Expert)
  • Ender 3 S1 Operation
  • CNC Routing
  • Sheet Metal: Laser Cut / Bend / Weld
  • MDF & Plywood Workshop
  • Rotational Moulding (Theory)
  • Support-Free Design
  • Materials: PLA, TPU, Mild Steel, Ply
  • Rapid Prototyping & Iteration

C — Electronics / Tech

  • C++ / Arduino Programming
  • MPU6050 Gyro/Accel Integration
  • WS2812 RGB LED Systems
  • Circuit Design & Debugging
  • Physical Computing
  • Sensor-Driven Interaction
  • Embedded Wearable Systems
  • User Research & Surveys
  • Product Costing & BOM
§06

Education & About

2024 – Present

BA Industrial Design

The Open Window Institute, Stellenbosch

2023 — Passed with distinction

Higher Certificate in Design Thinking

Greenside Design Center

2022

National Senior Certificate

Selborne College

Undergraduate Industrial Design practice at Open Window, School of Creative Technologies, currently at ID 300 level. The work moves between product design, creative computing, and visual communication theory — assessed as much on fabrication and electronics as on research and academic writing.

Based between Cape Town and Stellenbosch, the practice favours projects that force a decision: a material spec'd, a tolerance held, a circuit that either works or does not.

Languages: English (Native / Full Professional), Afrikaans (Proficient)

Film & Media

600+ films reviewed on Letterboxd. A deep appreciation for narrative structure, visual storytelling, and cinematic design language — a direct lens into how humans process pacing, emotion, and detail.

Music & Sonic Design

69,000+ minutes of music annually. A passion for how audio shapes user experience and emotional response.

Film, music, and physical discipline aren't hobbies — they're research into how humans connect with objects, spaces, and experiences.