Objective

The Luggage Rack was designed as an enhancement of traditional suitcase holders used in hotels and guest accommodations. The primary goal was to improve functionality by incorporating a removable laundry bag, providing an added feature that simplifies packing and unpacking for guests. The design needed to maintain the portability and durability of standard racks while offering additional storage for laundry without compromising aesthetics.

1. Concept Development

The design process began with understanding the needs of hotels and frequent travelers. Research identified several key pain points with traditional luggage racks:

• Limited Functionality: Standard racks only hold luggage, lacking any additional utility for guests.

• Durability Issues: Frequent use in hotels often led to wear and tear, especially on straps and joints.

• Storage Challenges: Some racks were bulky and difficult to store when not in use.

From these insights, we established the following design objectives:

• Added Functionality: Integrate a detachable laundry bag to hold used clothes, improving guest convenience.

• Improved Durability: Use high-quality materials and sturdy construction to withstand frequent use.

• Compact Design: Ensure the rack folds flat for easy storage when not in use.

2. Sketching & Initial Concepts

Initial sketches explored ways to incorporate the laundry bag while maintaining the core functionality of the luggage rack. Key concepts included:

• Folding Frame: A collapsible X-frame design for portability and storage.

• Laundry Bag Integration: Positioned below the luggage straps to ensure the bag didn’t interfere with suitcase placement.

• Material Selection: Combining wood for aesthetics and stainless steel for structural reinforcement.

Three design concepts were presented to the client. The chosen concept featured a dual-purpose rack with nylon luggage straps on top and a removable laundry bag below, accessible via a magnetic attachment system.

3. 3D CAD Modeling

Using SolidWorks, the chosen concept was modeled in detail to optimize functionality and manufacturability.

a. Frame Design

• The frame used an X-bar structure for stability and folding capability.

• Hex nuts and shoulder screws were incorporated at pivot points to ensure durability and smooth folding action.

b. Luggage Support

• Nylon straps were used for the luggage surface, stretched across strap bars. The material was chosen for its strength and resistance to wear and sagging.

c. Laundry Bag

• A removable laundry bag was designed with a lightweight, waterproof fabric.

• The bag attached to the frame via powerful magnets and could be easily detached for washing or transport.

d. Additional Features

• A lower wooden shelf was added to store smaller items such as shoes or folded clothes.

• Rubber feet were integrated into the base of the legs to prevent slipping and protect floors.

4. Prototyping

The first prototype was created using a combination of wood, nylon, and 3D-printed components for testing purposes. Prototyping focused on:

• Frame Stability: Ensuring the X-bar structure could support heavy suitcases without wobbling or collapsing.

• Laundry Bag Attachment: Testing the strength of the magnetic connection to prevent the bag from detaching during use.

• Ease of Use: Verifying that the rack could be folded and unfolded smoothly and that the laundry bag was easy to remove and reattach.

Feedback from testing revealed that the rack was stable and functional but needed some adjustments to improve usability:

• The magnets were replaced with stronger versions to hold heavier laundry loads.

• The folding mechanism was refined to reduce friction and improve ease of storage.

5. Testing & Refinement

The second prototype incorporated the feedback and underwent more rigorous testing:

• Load Testing: The frame was tested to hold weights up to 100 lbs, simulating heavy suitcases and multiple items on the lower shelf.

• Laundry Bag Stress Testing: The fabric was tested for tear resistance and waterproofing to ensure durability.

• Longevity Testing: Simulated folding and unfolding cycles confirmed that the pivot joints could withstand prolonged use without loosening.

Additional refinements included:

• Shoulder Screws with Lock Washers: Preventing joint loosening over time.

• Metal Rod Reinforcements: Adding support to the lower shelf for better weight distribution.

• Strap Width Adjustment: Slightly widening the nylon straps for improved stability and aesthetics.

6. Final Design and Manufacturing Handoff

The final design combined functionality, durability, and style, making it suitable for both hotel and home use. Deliverables included:

• 3D CAD Files: STEP and STL files ready for manufacturing.

• 2D Technical Drawings: Detailed part drawings with dimensions, tolerances, and assembly instructions.

• Material Recommendations:

  • Frame: Sustainable wood with a clear lacquer finish for aesthetics and protection.

  • Hardware: Stainless steel for all screws and nuts to prevent rust.

  • Straps: Heavy-duty nylon for long-term use.

  • Laundry Bag: Waterproof polyester with reinforced stitching.

• Assembly Instructions: Clear guides for assembling the frame, attaching the straps, and securing the laundry bag.

Manufacturing was optimized for a combination of woodworking and metal fabrication, ensuring a cost-effective and high-quality product.