Omar Serroukh

Form and engineering,
decided together.

Footpeg

Titanium, 219 grams, shaped by its own load path.

Stark Future, 20261 / 6

A footpeg for the Stark Varg Skugga, longer to fit military boots and lighter than the original.

Two load cases gave a diagonal main rib. Three passes removed everything that carried nothing: 306, then 246, then 219 grams, at a safety factor of 1. The part is set up for titanium powder-bed printing, 42 to a plate, with a jig that holds it while the spring seat is machined.

Brief
Stark Future with Elisava
Support
160 × 50 mm
Angles
5° and 85°
Mass
306, 246, 219 g
Peak stress
916.7 MPa
Tip deflection
3.43 mm
Build
42 per plate, 7 × 6
Tools
Creo, Inspire, Bambu Studio, nTop
Footpeg presentation with Stark Future context
Presentation frame — final footpeg geometry paired with the Stark Future / Varg Skugga use context.
01

Built for the worst case on the trail.

The footpeg has to hold up in a rough off-road setting — a heavily kitted rider, stiff boots, vibration, mud, the occasional second foot resting on it. That pushed the project past styling and into the full chain from parametric geometry to printed titanium.

02

Fixed interface, longer support, controlled geometry.

A parametric skeleton controls the critical dimensions: 160 mm length, 50 mm width, 5° inward tilt and 85° relative to the side plane of the motorcycle. The CAD work resolves the transition from the bike interface to a longer, lighter support surface.

Final CAD footpeg geometry
Final CAD: open walls, diagonal ribs, grip teeth and mud-evacuation voids.
Physical footpeg prototype
Physical prototype showing the final structural language as a real component.
03

The rib pattern comes from the load path.

Two load cases mapped the structural behaviour: 5 kN at two-thirds of the support plus 5 kN frontal load; and 3 kN at one-third and two-thirds plus the same frontal load. Both studies pointed to a diagonal main rib with secondary reinforcement near the interface and tip. The final geometry reaches the minimum safety factor target of 1. Maximum von Mises stress appears around the interface and decreases through the rib network. Maximum displacement is located at the far tip and remains controlled at 3.43 mm.

Topology optimisation output
Topology output used as the structural map for the diagonal rib system.
Footpeg stress simulation
von Mises simulation: 916.7 MPa max, then 468.8 MPa and 238.8 MPa through the component.
Footpeg displacement simulation
Displacement simulation: 3.43 mm maximum deflection at the far tip.
04

Print orientation, build plate and jig close the loop.

Bambu Studio was used for rapid orientation studies, then nTop for support generation and build-volume distribution. The final orientation is 40° in X and 27° in Y, with an estimated 22.3 g of titanium supports per part. The jig fixes the printed part for repeatable machining of the spring-hole interface.

Footpeg support strategy
Support strategy: print orientation and support bars prepared for metal additive manufacturing.
nTop build volume study
nTop build-volume study: 42 footpegs in a 7 × 6 distribution.
Footpeg machining jig concept
JIG concept: lower cavity and upper lock for repeatable post-machining.

The result isn't only a lighter footpeg. It's the full route from a use case to a printable titanium part: parametric model, topology study, FEA, print setup. For me the route is as much the project as the part itself.

Gÿro

A prosthesis that breathes.

External breast prosthesis, 20262 / 6

Silicone prostheses are heavy, hot and hard to wash.

Gÿro is a gyroid lattice in TPU 98A, printed by Multi Jet Fusion. It is open, so air and water pass through it, and tunable, because wall thickness sets how soft it feels. An internal tree carries the load where tissue would be denser. It is generated from a scan, not cast to a size.

Concept
Customised external prosthesis
Problem
Heat, weight, sweat
Structure
Gyroid and internal tree
Material
TPU 98A
Process
Multi Jet Fusion, vibratory polish
Reference
B cup, 63.0 × 99.6 × 121.4 mm
Tools
Grasshopper
Complete render of Gÿro gyroid breast prosthesis
Full render. A porous gyroid TPU volume designed to reduce weight, create airflow and behave closer to soft tissue than a solid silicone mass.
01

Function before appearance.

It's a scan-based prosthesis, and the gyroid body does most of the work — softness and airflow. An internal tree adds support, the edge keeps it off the skin, and a textile layer makes it comfortable to wear all day.

Transparent render showing internal tree structure
Transparent / internal. The inner tree structure explains how the prosthesis gains support without becoming a closed heavy volume.
02

The surface is the mechanism.

The gyroid is the core functional decision. Its continuous porous wall creates an open structure for airflow and cleaning, while the thickness and density can be tuned to approach a soft viscoelastic response.

Zoom of gyroid porous surface
Zoom. Porosity is not decorative: it controls ventilation, surface access and mechanical softness.
TPMS comparison showing Gyroid, Schwarz, Lidinoid and Split P
TPMS choice. Gyroid is selected because its continuous and near-isotropic behaviour fits a soft-body prosthesis better than directional patterns.
03

The object is generated, not sculpted.

The model is built as a parametric system: breast volume, gyroid field, trimmed lattice, internal branching and controlled density. This makes the prosthesis adjustable to different scans and cup references instead of being a single fixed shape.

Plan and dimensions of Gÿro prosthesis
Plan / spec. B-cup reference dimensions: 63.0 mm, 99.6 mm and 121.4 mm.
Breast anatomy reference with ligaments and glandular tissue
Anatomy. The internal tree references denser support structures; the gyroid body references the softer adipose behaviour.
Grasshopper definition for gyroid and internal structure
Definition. Grasshopper controls the gyroid field, volume trimming and internal branching structure.
04

Porosity comes from structural logic.

Natural cellular systems and breast biomechanics explain the project’s structure. The prosthesis needs lightness, distributed load paths and differentiated support between softer adipose behaviour and denser internal tissue zones.

Biomechanical study of breast internal components
Biomechanics. Different tissues and ligaments respond differently under motion, so the prosthesis cannot behave like one uniform block.
Natural cellular references
Natural references. Cellular structures show how porosity can distribute material without losing continuity.

Gÿro is really a small material system: a scan sets the fit, the gyroid TPU makes it soft and lets it breathe, an internal tree carries the load, and MJF prints it. Where I'd take it next is the lattice itself — tuning density and wall thickness until it behaves more like real tissue.

Grafting tool

One hand, one blade, three cuts.

Generalitat de Catalunya, 20243 / 6

Stone pine is grafted with a scalpel, 18 to 20 an hour, in a season of three to four weeks.

This tool peels bark through two holes that widen as the handles open, then guides a vertical, a horizontal and a diagonal cut with one catalogue blade. Six parts, M3 hardware, no glue. The blade changes with one screw.

Client
Generalitat de Catalunya
Use
Pinus pinea nurseries
Window
3 to 4 weeks
Manual rate
18 to 20 grafts an hour
Scion
Under 10 mm
Parts
Six, M3, 40 mm blade
Safety factor
16.25 torsion, 10.57 peeling
Final side render of the grafting tool
Main render. Final side view of the articulated grafting tool: adaptive peeling tip, hinge, spring logic and blade housing.
01

One tool for peeling and cutting.

Stone pine grafting is still performed manually with scalpels: low throughput, short seasonal window, high skill dependency and blade-injury risk. The tool compresses peeling, vertical cut, horizontal cut and diagonal cut into one guided handheld system.

Vertical render of the grafting tool
Vertical render. The tapered handles and central hinge read as a compact plier-like tool.
02

Guided notches and adaptive holes structure the action.

The tip includes two circular holes for bark peeling by rotation. Their effective diameter changes with the opening angle of the handles, adapting to different branch sizes. Behind the tip, the guided notches stabilise the scion/rootstock for vertical, horizontal and diagonal cuts with one replaceable blade.

Close-up of peeling holes and guiding geometry
Tip detail. Adaptive peeling holes plus guiding geometry: function is concentrated at the nose of the tool.
Alternate side view of the grafting tool
Alternate side. The blade housing, hinge and two-handle relation become legible in profile.
03

Simple assembly, standard parts.

Six-component logic: top handle, bottom handle, 40 mm razor blade, torsion spring, two M3 screws and two M3 nuts. The blade can be replaced by loosening one screw; no adhesives or welds are required.

04

High safety factor, clear critical zones.

FEA checked spring torsion and peeling load. With PVC as reference body material, the study reported 2.77 MPa maximum von Mises stress in torsion and 4.257 MPa in peeling, both far below the 45 MPa yield strength. The resulting safety factors are 16.25 and 10.57.

Overall finite element analysis of the grafting tool
FEA overall. Stress concentrates around hinge transitions and local feature changes.
Detailed finite element stress view near the notch
FEA detail. Critical transitions around the peeling zone become clear for radius/thickness refinement.
05

Robust polymer body, metal blade, forestry setting.

The design language stays direct: matte polymer volumes, exposed metal hardware, visible hinge logic and a replaceable blade. The contextual reference is the stone pine environment, because the object belongs to a specific agricultural process.

Material palette with matte and metal spheres
Material cues. Matte structural plastic + metal hardware + stainless blade.
Stone pine tree reference connected to grafting context
Context. The project is tied to stone pine production and nursery work, not a generic gardening tool.

The aim was a tool a nursery could keep using, not a one-off prototype — off-the-shelf M3 hardware and a catalogue blade you change with a single screw. Next I'd work on the grip and add a cover for the blade in transport.

EV charger

Every state in one line of light.

Simon, 20264 / 6

A home charger for the Simon Challenge.

The electronics stayed. The shell, the diffuser and the service access were redesigned so one continuous perimeter of light carries every state, and the front can stay plain. The diffuser lives inside the enclosure section instead of on its face.

Brief
Simon Challenge 2026
Scope
Enclosure, diffuser, access
Kept
Power and LED boards
Media
Renders, exploded views, motion
01

Mechanical redesign around a fixed electronic core.

The power board and LED board stay untouched; the work goes into the shell, the diffuser path and how the unit is opened for service. The point was simple: make the status readable at a glance and the charger easier to install and live with.

Ping-pong GIF of Simon charger motion
Motion study. A short looping animation of the charger.
Exploded render of the EV charger
Exploded render. The component stack is separated to explain assembly and maintenance.
02

The LED is treated as a perimeter interface, not as an added indicator.

The light path wraps the geometry and converts status feedback into a readable spatial cue. The diffuser is integrated into the shell section rather than applied as a separate frontal token, which gives the product a more coherent visual signal both close-up and from distance.

Section detail of the LED diffuser integration
Section detail. The LED diffuser is resolved directly in the enclosure section.
Shell development views of the charger enclosure
Shell studies. Upper body, lower body and top cover are tuned as a family of coordinated surfaces.
Second ping-pong GIF of Simon charger motion
Assembly. A short looping animation of the component stack.
03

Cover, diffuser, board and base are separated into a readable stack.

The assembly is organised into an upper cover, the LED support and diffuser, the internal power board, protection elements and the lower housing with cable entry. This reduces ambiguity during assembly and gives each part a clear role.

Front view render of the charger
Mounted front view. The front face is simplified so the perimeter line remains dominant.
04

The form is reduced to a robust enclosure with a single recognisable signature.

Instead of breaking the front into panels and details, it uses a few chamfers, a recessed centre and the light loop to hold everything together. It ends up reading as a compact, protective object you recognise as a home charger.

The redesign leaves the electronics alone and reworks the body around them. The perimeter light does the signalling, so the front face can stay plain, and the exploded view shows how the whole thing comes apart for service.

re-Flex

One polymer, nothing to separate.

Steelcase Flex, redesigned, 20265 / 6

The Steelcase Flex table in a single polymer.

One material means nothing to separate at end of life and nothing to assemble at delivery. That decision is where the reported 58 % lower impact comes from. The table comes back through a collection loop for reuse or regeneration.

Route
Proposal II, monomaterial
Material
Polypropylene
Assembly
None
Impact
−58 % reported
Buckling
5 mm at 400 N, 6.6 mm at 900 N
Loop
Use, return, regeneration
Final redesign renders of the re-Flex table
Final Proposal II redesign. Monomaterial PP body, integrated lower shelf, wheel system and no user assembly.
01

Proposal II: monomaterial PP table.

The final concept is not a mix of the three early routes. The chosen proposal is the monomaterial one: a recyclable PP table where the product language, structure and circular model all point to the same decision.

Proposal II monomaterial table
Proposal II. The monomaterial PP route, developed in full.
02

Make the table easier to produce, recover and recycle.

The redesign moves away from an assembled object made from several materials. A single PP body reduces separation problems, simplifies the product story and makes the return loop more believable.

Render details of the re-Flex table
Product details. Variants, lower shelf, wheel detail and continuous structural language.
03

The numbers behind the monomaterial decision.

The comparison quantifies why the monomaterial route was chosen: a reported 58% reduction in environmental impact against the multi-material original.

Comparative environmental impact chart
Comparative impact chart. The monomaterial route is the relevant result, with a reported 58% environmental impact reduction.
04

Three load cases, three buckling results.

Each case reports its applied load and the resulting buckling deflection, read directly from the simulation.

900 N load simulation
900 N Buckling 6.6 mm
400 N buckling simulation
400 N Buckling 5 mm
05

How the table re-enters the loop.

The lifecycle and business diagrams map the full circular path: recovery, transformation, fabrication, use and return, reintegration and second life.

Circular lifecycle diagram
Lifecycle diagram. Recovery, PP regeneration, regional manufacturing, distribution, use and reuse.
Business model diagram for re-Flex table
Business model diagram. Collection, transformation, manufacture, use and return, followed by reintegration or second life.

re-Flex commits to one route: a single-material PP table. Because it is one polymer throughout, it needs no sorting to recycle and no assembly by the user, and it can re-enter the loop at the end of its life. That one decision is where the 58% impact reduction comes from.

Xatrac

The feed shows the shock. This shows the conditions.

News interface, 20266 / 6

A news interface that reads an event as a set of causes.

It collects several accounts, places the event among the countries and conditions behind it, compares how each outlet framed it, and keeps visible what nobody knows yet. Where the evidence is thin, it shows the doubt.

Context
Crossover project, Love and Violence
Focus
Generative media, causal mapping
Logic
Event, context, perspectives, causes, uncertainty
Motion prototype, with sound.
01

A platform for reading conflicts through connections.

The MVP uses generative technologies to gather multiple news accounts, compare their perspectives and organise them with contextual data so the reader can understand an event as a system rather than as a single headline.

02

The feed shows the shock. Xatrac shows the conditions.

Wars, climate events and political crises are usually consumed as isolated fragments. Xatrac slows that logic down and exposes causes, actors, narratives and gaps in the evidence.

03

Event, context, perspectives, uncertainty.

Collect the event. The system starts from a current conflict or crisis and pulls different journalistic accounts instead of relying on a single source.

Add structure. Country data, historical conditions and surrounding relations are attached to the event so the headline can be situated.

Read perspectives. AI is used to compare the narratives, detect emphasis and reveal where the accounts converge, diverge or omit information.

Map uncertainty. The interface returns a causal map that helps the user see connections and also keeps the unknown parts visible.

04

The news feed isolates effects from causes.

Most interfaces privilege immediacy because speed increases consumption. That mechanism compresses time and hides the structures that produce the event, so the reader reacts to impact without seeing the wider configuration.

Xatrac network field
Relational field. The project treats the event as a dense set of unstable links instead of a line of headlines.
Media mediation reference
Mediation. Screens do not simply show events; they select, crop and stage them.
05

Direct violence is visible. Structural violence is slower and harder to see.

Xatrac links immediate events with long-duration pressures such as unequal resources, constrained mobility, institutional force, trade dependencies and the media narratives that make those conditions appear natural.

Project map fragment
Interface field. Nodes, routes and empty zones communicate how evidence, actors and relations are distributed.
Theoretical network strip
Graphic syntax. The network strip is used as a compact layer to maintain continuity without wasting space.
06

Collect, compare, connect, explain, refuse false certainty.

The intended workflow gathers different sources, compares their framing, connects the event to broader structures and proposes explanations only when the mechanism is grounded. When the evidence is weak, the system must show the doubt instead of fabricating closure.

Xatrac is the most experimental case in the portfolio because the designed object is not a physical artefact but a reading system. The value of the project comes from how it reorganises information: it helps the reader move from headline shock to contextual understanding by revealing actors, relations, causes and uncertainty inside the same interface.

Renders

Render sets, grouped by object. Each opens the full set.

Studies

Nine geometry studies in Grasshopper: recursion, surfaces, lattices, helices.

Recursive branching structure
Recursive branching structure Self-similar growth resolved into 1,000+ generated curves from a single parametric definition.
Twisted parametric vessel
Twisted parametric vessel Rotational surface driven by section profile and controlled twist along the axis.
Control-point lofted surface
Control-point lofted surface A doubly-curved patch driven by a movable grid of control points — the saddle geometry follows the points.
Ribbed vessel of revolution
Ribbed vessel of revolution A profile curve swept around the axis into stacked contour rings, with an axial twist running through the body.
Voronoi cell box
Voronoi cell box A bounding box subdivided by 3D Voronoi cells from scattered seed points, then wired into a strut lattice.
Cellular shell on a freeform volume
Cellular shell on a freeform volume An organic mesh wrapped in a cellular lattice — a lightweight open shell standing in for a freeform solid.
Double helix
Double helix Two phase-shifted helices bridged by rungs and swept as a single tube — a DNA-style strand from a parametric path.
Twisted tower
Twisted tower Stacked cross-sections rotated incrementally up the vertical axis, then contoured into a ruled, fluted tower.
Helical spire
Helical spire A spiral contour lofted into a tapering conical spire — pitch and taper set the depth of the flutes.

Images

I photograph and film. Concrete, light, people at the edge of a frame: the same attention that decides how an object is seen.

Essentials
Aiko
Clip 04

Information

I study industrial design engineering at Elisava, Barcelona. My work usually starts from a constraint, what a part has to carry and how it has to be made, and the form follows from there. Engineering and appearance get decided together, not one after the other.

What I keep coming back to is the point where an object stops looking styled and just looks right for what it does. A prosthesis that fits one body. A footpeg that survives a race.

I also photograph and film. Deciding how an object is seen is part of deciding what it is.

Education
Industrial Design Engineering, Elisava and UVic-UCC, Barcelona
CAD
Creo, SolidWorks, Grasshopper, nTopology
Simulation
FEA and CFD, topology optimisation, TPMS lattices
Methods
Ashby and GRANTA, DfAM and DFMA, prototyping
Programming
Python, C#, Arduino
Languages
Spanish, Catalan, English, French (basic), Arabic (basic)
Status
Open to internships, Barcelona or relocation

Read

  • Otl Aicher, The World as Design
  • Henri Lefebvre, The Production of Space
  • Mark Fisher, Capitalist Realism

Watched

  • Terrence Malick, Knight of Cups
  • Jean-Luc Godard, Tout va bien
  • Michel Ocelot, Azur et Asmar

Listened

  • NTS Radio
  • Brian Eno
  • Arca
  • Dean Blunt

Looked at

  • Dieter Rams at Braun
  • Richard Sapper
  • Otl Aicher and the HfG Ulm
  • Peter Saville for Factory
  • Carsten Nicolai
  • NASA flight hardware

oserroukh@outlook.com

LinkedIn

This site is one hand-written file: no framework, no page builder, no tracking. Set in Archivo. Images load as you reach them and every one is sized in advance, so nothing jumps. Motion is limited to one camera push per chapter and stops if your system asks for less.