At Arrival Automotive, I led the development of the bus passenger seating system and wheelchair zones from initial concept to final production, achieving certification under ECE Regulation 107. Collaborating closely with the design team, I provided technical guidance across various materials and manufacturing processes, including complex plywood curvature, rotationally overmolded metallic backrests and armrests, composite panels and upholstered foam assemblies. A key focus was durability and ease of maintenance, leading to an innovative removable upholstery jacket with a drawstring for a secure fit without adhesives. Consideration for end-of-life ensured materials could be easily separated and recycled. Throughout the various iterations of the seat, I leveraged simulation tools(including topology optimisation), physical prototyping, and rigorous testing to develop a robust solution that exceeded weight, cost, and performance targets.
Client. Arrival Automotive
Design. Jason Kline, Bernhard Hierner
Engineering. Alex Keegan
The Arrival Bus stands out by prioritising passenger experience, with features like the innovative stop-request interfaces. This component integrated capacitive sensing technology within an injection-molded plastic housing, with engineered refractive geometry to enhance LED visibility. The design also included a PCB with strategically placed LEDs and vibration modes for haptic feedback, improving the experience for passengers with impaired vision. This project showcases my ability to collaborate with lighting and electrical experts while maintaining the vision of the design and ergonomics teams, with minimal compromise. Integrating the touchpoint and accessories, such as hanging hand holds, into the bus poles required meticulous simulation and testing, ensuring the premium passenger experience was achieved.
Client. Arrival Automotive
Design. Bernhard Hierner
Engineering. Alex Keegan, Sergey Popovs
This project represents a period of design and manufacturing innovation for Proform Plastics, A New Zealand based manufacturer and supplier of 4x4 accessories. Proform thermoform ABS plastic on site so my involvement in the Sportlid III development was in both the design and manufacturing sectors of the company. Design; surface styling, rigid frame and hardware, moulded plastic parts, pneumatic mechanical hinge. Manufacturing; water-cooled aluminium thermoforming mould, wall mounted vacuum fixture for CNC robot trimming of plastic skin, assembly table. Unique products were developed for major 4x4 brands - Ford, Nissan, VW, Toyota, Holden, Mazda.
Client. Proform Plastics, NZ
Design & Engineering. Alex Keegan & Andrew Porter
The Loadmaster exhibits an innovative approach to cargo management for 4x4 utility vehicles. Traditionally, the vehicle deck is a large space that cargo can move around on during travel. Solutions to this problem are often clunky and offer limited partitioning options. The trick to this products versatility is in the telescopic arm and mounting points which can swivel up to 45 degrees, even mounting to the front rail if necessary. I worked closely with our manufacturers in China to arrive at a solution that ticked all of the boxes; robust, attractive & affordable.
Client. Proform Plastics, NZ
Design & Engineering. Alex Keegan
The Tango Vehicle Transformation System enables user personalisation through interchange of an array of accessories, including the Sportlid III and Loadmaster. My role in this project was to take the proven concept and role out the Tango for various vehicle models, each with unique geometry, utilising universal tools and components as much as possible. Throughout this time I worked closely with our manufacturers to refine designs and specifications, quality check sample product, test fit to vehicles, develop fitting instructions and sign off the products for distribution.
Client. Proform Plastics, NZ
Design & Engineering. Alex Keegan, Andrew Porter & Steven Riddle
Escape Coffee is a surf shop, coffee roasting house, skate bowl, Kombucha bar and music hub in New Plymouth, A seaside town in New Zealand. The heart of the brand identity is the tipi, a symbol of the freedom to escape! I was commissioned to design three things: An Illustrated family of coffee cups that embodied the brand story; design a light box to advertise their infamous kombucha brew; engineer a large steel sign that would be mounted high on the street side and visible from afar.
Client. Escape Coffee Roasters
Design & Illustration. Alex Keegan
My final thesis at university looked closely at digital manufacturing technologies and the notion of mass customisation, as opposed to the traditional approach of mass producing identical products. The product is a complete user experience that encompasses the design, assembly and playing of a musical instrument, an African inspired drum. The target users are children aged 6 to 12 so the design developed a quirky, fun aesthetic while remaining simple and intuitive to assemble.
Client. University Project
Design & Prototyping. Alex Keegan
In this colourful project I collaborated with Architect Robin Aitken to design and construct an interactive and versatile set for the dance show Gizza Hoon, directed and choreographed by Brigid Costello. The client required a set that would become a part of the dance choreography, taking on the movements of the dancers and if possible, dancing itself. The concept chosen for development became an integral part in the dance choreography as the dancers were able to interact with the pieces, controlling their helical flow from the stage gantry using pulleys.
Client. Pinwheel Dance Theatre
Design & Construction. Alex Keegan & Robin Aitken
