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P O R T F O L I O

C R E A T I V I T Y & S T R A T E G Y

" An idea is an amazing combination of previously unconnected elements"

John Grant

Design + Engineering?

Nowdays nobody questions the fact, that if companies want to keep growing in a

sustainable way from day to day, they must innovate. Innovation, at all levels, is without

doubt the key to move forward, to establish new challenges and targets, to better use the

company’s competitive potential, continuing to do things well, they have to think through

things better to overcome the competence. This innovation, as well as in products as in

services, must come from the hand of design, as a tool where creativity and knowledge

meet together. If design is to be effective, a certain degree of creativity, a good dose of prior

knowledge and information must be added, thus, it is key that in industrial design, design

and engineering go hand by hand, only this way can more innovative solutions be

achieved,solutions that add value, improve functions, make the brand stronger and create

a positive experience on customers.

It is about combining the hability of a designer to observe and sinthesize, and the

analitycal capacity of an engineer to unveil the root causes that are behind any problem.

A product design and engineering studio located in the

centre of Valencia (Spain), founded in December 1998 by Joan

Rocabert (Barcelona, 1968), with the objective of answering the

growing need of the industrial and product markets, to manufacture

goods and products with a sound design, that meets the

requirements of a customer environment every day more and

more demanding in all aspects such as quality, functional reliability,

aesthetic appeal, sustainability, etc.

In Mellow Design we believe that a correct brief and

definition, from the very early statges of the design process, is

the key for project success. For this reason we take a design

approach from a multidisciplinary perspective, considering from

the very beginning the natural and unavoidable relationship

between Design and Engineering, in order to solve and overcome

all the questions and restrictions, that any project imposes, cost,

manufactur ing feasib i l i ty, ergonomics, funct ion,…

Mellow Design develops and manages design up to

prototype production and run of small series. We develop Projects

in close collaboration with our clients and suppliers, this has taken

us to consolidate an extremely valuable net of profesional alliances

with expertise in different areas to ensure top quality results.

Our studio is divided in a main working area, a meeting

room and a small prototyping workshop, we also have available

a 300 sqm area on an industrial park warehouse, for works and

prototyping that require larger facilities.

The studio at full power has a creative and production

capacity of 6240 manhours per year, with the possibility to grow

in order to overcome peak workloads.

Currently, our activity is developed in automotive, nautical

and industrial industry.

Joan Rocabert

(Barcelona, 1968)

Management & Direction

Mechanical Engineering, Barcelona (SPA)

MSc in Fluid Dynamics, Cranfield (UK)

MA in Advanced Design Studies, London (UK)

Guillermo Bellod

(Alicante, 1974)

Industrial & Graphic Design

Fine Arts, Valencia (SPA)

Postgraduate in Sculpture &

Bronze casting, London (UK)

Sergio Sebastián

(Valencia, 1983)

Engineering & Product Design

Tecnical Engineering in Industrial Design,Valencia (SPA)

Floppy

(Valencia, 2008)PublicRelations

Philosophy and Services

We understand design in a global manner, not as a group of isolated disciplines, that’s

why we are interested on integral Works, where product design makes sense with marketing

strategies and all their different components, such as packaging, brochures and manuals,

commercial diffusion,…

In general we feel attracted to any activity field where innovation is required, in particular

we are interested in those companies that trust design as a powerful tool, those companies

that wish to innovate and grow, ultimately, those which assume controlled risks in order to

empower and maximize the efficiency of company resources, thus, creating new possibilities

and business opportunities.

We emphasize communication with our clients, especially at the beginning of the

projects, when working plans and strategies are defined, bearing in mind that activities must

flow as smoothly and efficiently as possible for the customer.

Additionally, we offer support to companies in different areas of industrial design and

engineering, such as project definition and planning, Project management, ideas and

concepts visual presentations, 3D development and surfacing, drafting, FEA and CFD

analysis, prototyping and modelling,…

c copyright Mellow Design 2010

Project:

Gota Light.

Concept:

How would it feel to be surrounded by a rain of

light drops? A scenery that could take us to a magical

place. They could be Perseids or St.Lawrence tears,

may be, a new form of liquid energy, perhaps, just

a short instant that can bring to us light and harmony.

Description:

Inspired by the high speed photography master

Harold Edgerton on his milk drops in 1953. Gota is

a frozen moment, that captures on its shape all the

energy, complexity and freedom. The piece is made

entirely in polyester resin, detail and shape continuity

are achieved, by a silicone mould that has no partition

lines. A GFRP Shell gives stability to the mould during

casting, vacuum casting produce very fine results

that require minimal post-processing.

Ilumination comes via LED technology, whose

properties are very low consumption together with

high light control, and over 50.000 h life span. The

base is made of a photoluminiscent material that

shines in the darkness, once the light is switched

off.

Gota is an example of emotional design, where

craftmanship during conception and modelmaking

is combined with technology to produce short runs

through vacuum casting process.

Client:

Mellow Design, Valencia ( Internal proposal ).

Year:

2009.

light


Project:

Mant Ray Light.

Concept:

Lamp inspired by the fluid motion of mant rays in

the sea. The light is variable in color and intensity.

Description:

This lamps represents an exercise of volume

generation from planar sections.The different sections

that produce the volume are cut using water jet

technology, the necessary information for the cut is

created by CAD. This technology produces clean

and precise cuts that require no post-processing,

Finally all parts are assembled together to shape

the lamp.

For the lighting, once again, LED technology has

been the one choosen, bearing in mind its low

consumption and long life properties, furthermore,

RGB leds are the ones used, which have high color

control with good dimming properties.

This system, due to its development and

construction simplicity, offers a wide range of

possibilities to produce large format lamps and

installations.

Client:


Year:

2010.


Project:

Tetris shelves.

Concept:

Modular shelving system with components, thatmake the shelves dynamic and transformable,evolving with the age and creativity of kids.

Description:

Tetris is a modular system where the well knownelectronic game has been materialised in amultifunctional piece of furniture, which is attractiveand cool as much as for the kids as for their parents.The different combinations and possibilitiesemphasize the communication between parents andkids, using the furniture as an educational tool, tokeep spaces tidy, to play with colours and shapesin the space, thus promoting creativi ty.

Iconographic shelves that try to minimise the kid-electronic game dependence, bringing back thepossibility of playing with classic games such as“noughts and crosses”, dartboard, basketball,…

The system has a huge versatility, since it cangrow in size, by adding new baseboards, as well asgame components and storage modules.

An important design target was to produce a pieceof furniture that can grow with the kids, creating anemotional link and developing spacial visionawareness. At early ages, the parents will be theones that have to reposition and play with themodules, following kids instructions, and as the kidsgrow, they will be the ones learning psicomotricityand precisión during assembly.

Client:

Proposal 3rd Design contest "María MartinezOtero", Santiago de Compostela (Spain).

Year:

2008.

HORIZONTAL POSITION (3-7 YEARS)

VERTICAL POSITION (7-11 YEARS)


Project:

Rock & Roll chair.

Concept:

Two-in-one, lounge chair and rocking chair in one

piece, a functional reversability exercise, by means

of a simple use concept, without assemblies or

mechanisms, swapping the use by simply rolling it

in a natural and intuitive way.

Description:

The R’n’R chair wants to recuperate the pleasure

of the old fashioned rocking chairs, combining it with

current lounge chair design, elegant and innovative,

ultimately, a new piece of furniture that can be made

and customize in different materials.

The chair’s structure is simple and robust, formed

by two laterals shaped with smooth lines, which

facilitates rolling to change chair’s use, side view

reinforces the graphic character of the chair. The

whole piece is solidly assembled thanks to four tubes,

which hold on their exterior the foam cushions and

the textile seat.

Client:


Year:

2005.


Project:

Low Table.

Concept:

Low table that represents a step forward in the

concept of classic furniture, keeping a formal

synthesis of straight lines and mediterranean

inspiration. Sculptural element, functional and elegant,

where art and technology converge together.

Description:

Low table proposal for a new line of furniture, in

which the goal is to keep the philosophy and culture

of the client, with a piece that is elegant, solid and

of superior quality, where functionality comes with

a sculptural presence.

The top edge of the table is made of different

layers of coloured veneers, a slightly shaped milling

reveils new forms of ornamentation. The table is

mainly made of oak and walnut, the lower base is

all lined with fine leather to add a warm feel and

quality. One of the corners is eliminated, giving room

to a magazine holder and adding geometry on the

whole. The top board has plenty of room underneath,

and treasures a bottle cabinet in the centre. The

table presence is highlighted in low light conditions

thanks to LED i l lumination on the f loor.

Client:

Muebles Hurtado, Valencia (Spain).

Year:

2007.


Project:

Modular shelves system.

Concept:

Modular shelves system, keeping a formalsynthesis of straight lines and mediterraneaninspiration. Open modules allow the use of the systemas a dividing element in open spaces.

Description:

The system is a proposal for a new line of furniture,in which the goal is to keep the philosophy andculture of the client, with a piece that is elegant, solidand of superior quality, where functionality comeswith a sculptural presence.

The target was to create a system with a mínimumnumber of modules and large modularity, thecomponents are a base plus four open parallelepipedsand the union modules. The base, made in oak andwalnut, can grow the system in length, it also hasplenty of internal room for storage, the lower frontpanels are lined with fine leather to add a warm feeland quality. The top edge of the base is made ofdifferent layers of coloured veneers and a slightlyshaped milling reveils new forms of ornamentation.The top modules, also made of oak and walnut, aresimply open cubes, with a bright interior colourcoating, to which is feasible to add glass doors andshelves, without breaking the transparency of thesystem.

The assembly of the system is made through thelink modules, small boxes finely lined with leather,which hold the modules together simply by threadedrods, or alternatively with suction caps.

Client:

Muebles Hurtado, Valencia (Spain).

Year:

2006.


Project:

Ola chair.

Concept:

The Ola chair is inspired by the feeling of sitting

on a big vertical outlet of water. Ola is a turn-head-

piece with the invitation to be explored and feel the

different positions the user may take.

Description:

During the design process the intention was to

come up with a unique piece, easy to manufacture,

low maintenance and maximum commercial appeal.

Ola’s main characteristic is its capacity to adapt

to the different positions the user may take, the

reason for this is the volume that embraces the user

is formed by planar sections that can pivot radially

when pushed to the outside, thus molding the seat

according to the required ergonomics.

The chair is mainly formed by two groups of

elements, one fixed, which is the seat plus the

standing column with feet, and a second group of

mobile elements formed by the sections plus the

inserted cushions. These sections all have a lower

pivot on the central column, and are all joined together

thanks to a big elastic rubber ring, whose function

is to add the “spring back” feel on the seat and keep

the structure together.

Client:

2nd Design Competition “Mª Martinez Otero”,

selected and shown during the exposition at Casa

da Parra, Santiago de Compostela (Spain).

Year:

2006.


Project:

Clip resistance test gauge.

Concept:

Design, development and manufacturing of a testgauge to evaluate component clipping performance,verifying client requirements and process capability.

Description:

Design, development and manufacturing of a testgauge to evaluate component clipping performance,between radiator gril le and front bumper.

All trials and tests must be performed with thefront bumper assembled onto the front vehicle jig,a jig that reproduces all nominal dimensions andvehicle fixing points on the front side. The effort overthe grille must be done in compression, as it mustsimulate a low speed impact situation, applicationforce must be normal to the impact surface at alltimes.

The gauge must allocate a dynamometer able toread up to 2500 N, must also be able to collectdifferent data such as peak and continuous forces,as well as force vs displacements Information.

After considering all possibilities, a cantileverstructure that should fit onto the front vehicle jig waschoosen, which also have a movable tower thatwould hold the dynamometer and its applicationhandle. Such tower, due to its design, allows plentyof flexibility when performing the tests, as it mayfreely move over the plane YZ and can also varyangle of attack from 0 to 45º.

Client:

Faurecia Automotive Exteriors, Valencia (Spain).

Year:

2010.


Project:

Logo adherence test gauge.

Concept:

Design, development and manufacturing of a testgauge to evaluate logo bonding performance, onceis assembled over front grille, verifying clientrequirements and process capability.

Description:

Some of the requirements that car makers wantto verify with their suppliers, eventually are thebonding capabilities between components. This isthe case of the Logos used on some vehicles, whoseunion is made by a double sided sticky tape, andwhose performance is greatly dependent onmaterials, surface and process qualit ies.

The gauge must be such, that it firmly holds thecomponent that carries the logo, in this case a grille,ensuring that there is no deformation over the testcycle. Furthemore, the extraction force over the logomust be applied normal to its surface, as the logo ismade of a 0.5mm thin aluminium plate that could bedeformed and lead to undesired results.

The gauge, made of stainless steel, reproducesthe grille boundary conditions to obtain a real testingscenario. The logo extraction plate is made out ofcomposite, kevlar and carbon fibre, and copies thelogo shape to produce an even load distributionduring testing.

Client:

Faurecia Automotive Exteriors, Valencia (Spain).

Year:

2010.


Project:

Development, drafting and technical services.

Concept:

Engineering and technical services outsourcing.

Description:

Mellow Design has an engineering and design

team, with the latest IT technology and consolidated

experience in the industrial sector, to cover a wide

range of technical needs for companies, such as 2D

drafting, 3D development and surfacing, exploded

views and product tear down, complex CNC cutting

templates, problem and root cause analysis,

Rendering and 3D visuals, layouts, brochures and

technical manuals, mechanical and structural design,

FEA and CFD analysis, etc. Ultimately, our team

offers you a personalized service to understand your

technical needs, offering integral solutions to respond

to customer expectations.

Without doubt our target is to add value to customer

technical needs and activities, through a quick

integration in the company’s structure and working

culture, without extra-costs on training and with the

security of offering the best quality within the

established timing.

Client:

Aktrion, Audax, Faurecia, Erauto, Pujol Muntalà,

Tenso Cables, Tecniacero, Autalem,Tracbages,

Plastal, MSX International, JD Power and

associates…

Year:

1998 - 2010.


Project:

Strainers and particle extractors.

Concept:

Design and development of different types of

strainers for liquids and steam installations. Basket

strainers, centrifugal particle extractors, duplex basket

strainers in “D” and “H” configurat ion...

Description:

Strainers Design and development together

with the manufacturer. During initial design phases,

special attention was paid to improve filtering

performance of current models, obtaining, for

instance, an optimal stream centrifugal flow in order

to elimininate solid particles, by adding a tangential

inlet flow, and improving flow vorticity on the way up

to the outlet, by adding a special design plate on the

bottom of the strainer, all these lead to a better

filtering conditions reducing pressure lost too.

The extensive computer use during the design

process, allowed the optimisation all external

dimensions and volumes on current models, as well

as providing all the necessary information for drafting,

website, brochures,...

Client:

AJ Valvulas, Barcelona ( Spain ).

Year:

2006 - 2007.


Project:

Finite element analysis for a butterfly valve lockingsystem

Concept:

Linear static analysis design verification for a newdevelopment of a locking system for hydraulicalactuated valve.

Description:

IMS is a company dedicated to design, engineeringand manufacturing of an extense range of valveproducts for very different markets and a wide fieldof applications all over the world.

As part of their continuous improvement companypolicy, they went into re-design some of the lockingfeatures that were available for large hydraulicallyactuated butterfly valves, as old systems showed tobe highly time consuming to engage and release,for both open and closed valve position, a newsystem has been under study to reduce drasticallyoperation time.

The system is mainly composed by a hardenedstainless steel stud that locks any possible movementbetween the external valve chassis and the valveactuated lever, in the event of a hydraulic missfunction(forces can easily reach 10 Tm levels).

Finite element analysis has proven once again tobe a powerful tool, in order to check design reliability,reducing testing and implementation time, and helpingduring the design process to improve shapeoptimisation in order to have a robust componentwhile keeping materials and manufacturing withinthe cost margins.

Client:

IMS Valves, Barcelona (Spain)

Year:

2011.

Balancina

Pasador

Resultados del modelo sobre la balancinaEvaluación riesgo tensiones de Von Mises

Resultados del modelo sobre la balancinaEvaluación de las deformaciones

Máxima deformación0.267 mm

Resultados del modelo sobre el pasadorEvaluación riesgo tensiones de Von Mises

Von Misses 1044·E6 PaNivel de riesgo 1.74

98555 N

Resultados del modelo sobre el pasadorEvaluación de las deformaciones

Deformación Máx.0.04 mm

Malla de la balancina 29200 elementos

Malla del pasador 21400 elementos


Project:

CIP(Cleaning In Place) Washing cabinet.

Concept:

Design and development of a CIP washing cabinetto wash and recycle different sizes of plasticcontainers.

Description:

An extensive use of plastic containers for differentproducts, require a good recycling process andmachinery, so the client decided to build a specialwashing cabinet to suit their process.

The initial idea from the client was conceptuallypretty clear. It had to be a cleaning and desinfectioncabinet, able to treat 7 containers at once, with anautomated system controlled by a PLC unit, it shouldalso have a special compartment for manual cleaning.The cabinet must be able to be connected to theCIP (Cleaning in place) system of the company´s,pressurised system that carries water plus cleaningagents, at the same time, the installation should beclean and easy to maintain. From here design anddevelopment work started to produce all thenecessary information for manufacturing.

First studies lead to a simple stainless steelstructure with structural reinforcements, plus twosliding doors, all closing panels are made in 1mmthickness stainless steel, they all have a diamond-like bending to add structural stiffness. There is threewater tight compartments, manual and automatedwashings plus PLC area. The automatic washer jetsare designed telescopic and work under the effectof pressure. Finally, all draining water is collectedon the bottom tray.

Client:

Autalem, s.l., Barcelona ( Spain ).

Year:

2008.


Project:

Wrap-around rear projection screen.

Concept:

Design, development and manufacturing of a 130º

wrap-around screen for rear projections.

Description:

The client, whose main activity is the development

of software and hardware for the visual and digital

environments, required a functional prototype of a

wrap-around screen, as part of a images projecting

system that was under their development. With this

system the users get the image projected around

themselves, thus increasing considerably a 3D and

more real sensation.

The screen had to be very light and easy to

assemble and disassemble, it also had to locate 6

fiber optics sensors and all the wiring and electronics

to interface with the computer.

The screen itselfm, made out of a polypropilene

sheet is suported by a 3D frame, extremely light and

stiff, this is composed by two, top and bottom, arcs

made out of aluminium with an optimised section to

resist the bending moment from the PP sheet, both

arcs are united by two fiber carbon tubes, in which

interior run most of the wiring for the system, all the

electronics are carefully hidden under the bottom

arc.

Client:

Montesa Graphics, s.l., Valencia (Spain).

Year:

2009.


Project:

Renderings for floating modules.

Concept:

Rendering and images of movable floating modulesfor an architectural congress in Valencia.

Description:

As part of the fair FIMMA Maderalia, that tookplace in Valencia during November 2009, was thecongress of “Plastic composites in architecture ascreativity, innovation and competitivity factors”.

Some marine activities such as maintenance andsurveillance of fish farms, scientific studies in certainareas and ecosystems, marine engineering works,etc. have high personnel and equipment transportcosts associated, these may risk project profitabilityand feasibility.

Valencian shipyard Audax presented an alternativemovable architectural project to deal with theseissues.

The solution is a totally self-sufficient module,made out of composites with a very light and rigidstructure, easy to transport, locate and remove, aconcept similar to those in civil engineering wherecontainers are used as personnel rooms, toolingstorage rooms, etc.

The modules together with the ballast aretransported by boat, then they are placed in thedesired area and a large flexible and inflatable ringgives stability, which also works as a wavebreakerand mooring place for small auxiliary boats.

Client:

Audax, Valencia ( Spain ).

Year:

2009.


Project:

Formula Renault Van Diemen RF95.

Concept:

Update and component development for a formulaRenault with Van Diemen RF95 chassis, vehicle of“ARP Comperició” team during 2007 Cataloniahillclimb championship.

Description:

Part the improvements that the team planned for2007 season, were entrusted to Mellow Design.Thatwas the installation of a new Hewland Elite gearboxplus a better aerodynamic performance on the fronttrack.

In order to install the new gearbox to the currentchassis, new rear suspension components and fixingshad to be designed and manufactured, as the gearboxon these vehicles is used as a chassis extensionwhere rear suspension fits, bearing in mind thatgeometry settings had to be left intact in order tokeep car dynamics as original. Several dimensionswere taken on the car and then translated to CADenvironment for further development.

For the front aerodynamics improvement, a newwing was designed with a higher aero load persurface unit, extention flaps with a variable angle ofattack were added, in order to add aerodynamicsetting flexibility to optimise the car versus track.

A new improved design for the nose with a morecontemporary look was also done.

Client:

ARP Competició, Barcelona (Spain).

Year:

2007.


Project:

Classic speedboat restoration.

Concept:

Restoration and face-lift of a Glastron SSV144speedboat, keeping the sporty classic look, whilstimproving functionality and durability for daily or veryfrequent use.

Description:

Classic speedboat over 30 years old, that theclient wanted to recover for quater of the cost of anew boat of similar characteristics.

The engine, a two stroke 60 bhp Johnson,regardless of age had very few running hours, thus,it was only necessary to do an overall cleaning andgreasing plus some setting work. The SSV type hull(Super Stable Vee Hull), pioneered during the 70’sand still widely used on current planing models,needed reparation of breaks and delamination inonly 10% of its surface, the rest was ready forsanding, priming and final coating. The floor was allcovered on Vengé wood to improve comfort andappearance. The old aluminum double windscreenwas replaced by a finely made stainless steelwindcreen structure and a blue tinted one-pieceplexiglas, all the interior trimming was removed andreplaced by fantasy red veneers, some carbon fibrepanels and cream synthetic leather seats.

Weight distribution was also modified, by movingthe fuel tank to the front and increasing its capacityfrom 20L to 60L, thus improving planing capabilityand range. Finally all necessary intrumentations forsecure and comfortable use during day and nightwas installed on board.

Client:

Private.

Year:

2009.


Project:

Ford Bumpers.

Concept:

Technical services and development together withPD (Product Development) department of PlastalSpain, during the launch phases for the bumpers ofFord vehicles, Cmax, Focus, Fiesta and Mazda2.

Description:

During the launch of a vehicle, all differentcomponents must conform, prior to production, to awide set of requirements in a limited time span. Thishas to be accomplished through the different launchphases, where suppliers must meet all Clientrequirements in terms of functionality, finish, assemblyfeasibility and costs.

These requirements and validations are even morecritical for the bumpers, components that due to theirprotagonism on the vehicle play a very importantrole in terms of finish and functionality. All differentmanufacturing processes, injection, assembly anddelivery must be monitored and adjusted to meetthe targets.

Mellow Design has a in working relationship withPlastal Product Development making tests, checksand validations from the first injected samples up tofinal product approval for production.

Client:

Plastal Spain, s.a., Valencia.

Year:

2003/2004/2005/2007/2008/2009/2010.


Project:

Elevator for a Gos 16.

Concept:

Mooring elevator design for a GOS16 boat.

Description:

The foundation “Un Mar Sin Barreras” (A SeaWithout Borders) works for the integration of disabledpeople and other collectives that are under the riskof social exclusion, working through the nauticalworld and paying special attention to integrate in aworking and social environment.

Mellow Design has collaborated several times withUMSB Foundation, giving lectures and workshopson maintenance and restoration of fiberglass boats,as well as participating in boat adaptations anddesign.

UMSB has a sailing school with special boats fortwo disabled crew members, the GOS 16. The speedand performance of these boats are dependent onthe conservation state of the hull, so algae and smallincrustations during mooring are not desirable. Inorder to overcome this issue during mooring, aspecial lift was designed, to manually lift the boatover the water’s surface, this would also help crewmembers, with access difficulties, to get on board.

A simple stainless steel structure, plus a lift rollingon nylon rollers, can be actioned by a single person,locking the boat’s position at the desired height.

Client:

UMSB, Valencia (Spain).

Year:

2005 - 2006 - 2007.


1.475 m2

4.193 m2

3.194 m2

Area total = 8.862 m2

Project:

Keel design and optimisation.

Concept:

Keel for an ocean sailing boat.

Description:

The design and construction of a sailing boat

requires the knowledge of specific subjects, from

the very beginning to f inal construction.

Different parameters and elements in a wide range

of subjects, such as fluid dynamics, stability and

manufacturing processes are required to take

compromise solutions in order to achieve the boat’s

targets.

The design and manufacturing of the keel -key

element to achieve an equilibrium between

aerodynamic and hydrodynamic forces- is not an

exception. It is critical to do a good weight analysis

and distribution, plus minimising hydrodynamic drag

resistance.

Mellow Design has been collaborating with Audax

Shipyard, during the design process and

manufacturing of the casted keel in order to achieve

the desired performance.

Client:

Audax, Valencia (Spain).

Year:

2009/2010.

C/ Bany dels pavesos 3, pta.2Valencia 46001 Spain

Tel.&Fax. +34 96 392 04 22

[email protected]

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