DIY Design & Fabrication
CMU 24-672 Fall 2017
Task 1: Lego Drawings
Drawn for Task #1, we had to choose three unique Lego Pieces and draw various orthographic and 3D views of each individual piece along with a unique 3-part assembly.
Drawn for Task #1, we had to choose three unique Lego Pieces and draw various orthographic and 3D views of each individual piece along with a unique 3-part assembly.
Project 1: mugghällare
Here are the process and final photos for the coffee cup holder designed for MYKEA.
We were tasked with creating a sleek and simple acrylic coffee cup holder. This coffee cup holder consists of two pieces that have been heat treated together. I really wanted to keep the design for this cup holder simple. I focused on clean lines and comfort rather than flashiness while designing this. For more information on this product, please refer to the product flyer below.
Here are the process and final photos for the coffee cup holder designed for MYKEA.
We were tasked with creating a sleek and simple acrylic coffee cup holder. This coffee cup holder consists of two pieces that have been heat treated together. I really wanted to keep the design for this cup holder simple. I focused on clean lines and comfort rather than flashiness while designing this. For more information on this product, please refer to the product flyer below.
Process Photos
Final Photos & Product Flyer
Project 2: hexa
Here is the documentation for a hanging lamp that I produced.
We were tasked with creating a lamp constructed out of cardboard and paper without any binding agents. The goal of this project was to create and express form by using planer elements combined with the effects of light and shadow. My main inspiration for this lamp came from geometric shapes, patterns, and objects along with crystals, metals and patterns that are found in nature. My main construction inspiration came from interlocking joints and slotted cardboard.
Here is the documentation for a hanging lamp that I produced.
We were tasked with creating a lamp constructed out of cardboard and paper without any binding agents. The goal of this project was to create and express form by using planer elements combined with the effects of light and shadow. My main inspiration for this lamp came from geometric shapes, patterns, and objects along with crystals, metals and patterns that are found in nature. My main construction inspiration came from interlocking joints and slotted cardboard.
Moodboard Showing My Sources of Form Design Inspiration & Mechanical Design Inspiration
Process Photos
Final Photos
Task 3 & 5, Project 3 & 4: hand
Below is all the documentation for the tasks and projects concerning a 3D printed hand.
Below is all the documentation for the tasks and projects concerning a 3D printed hand.
Task 3 - Super Model
Completed for Task #3, I downloaded an existing 3D file from GrabCAD and kept it as is. I wanted to focus on drawing a hand, since figure drawing is something that I lack tremendous skill in.
Completed for Task #3, I downloaded an existing 3D file from GrabCAD and kept it as is. I wanted to focus on drawing a hand, since figure drawing is something that I lack tremendous skill in.
3 orthographic sketches of the design
3 perspective marker renderings of the design
Perspective view screenshot from SolidWorks
Perspective view screenshot from SolidWorks
Perspective view screenshot from SolidWorks
Project 3
Here is the documentation for a small hand that I 3D printed.We were tasked with 3D printing a personal keychain using the NVBOT located in the IDeATe Fabrication Lab. The small hand was printed using grey PLA filament. Due to the specified size constraint, I printed a very small object. When it came to sanding and polishing the object, I was worried that this process would cause the smaller parts of my model to come off or fall off, which is why my printed part is not completely polished. It was also difficult to completely sand and polish the part due to its small size. This is meant to be cast into a mold, so prior to molding I will paint the object to make it more smooth. Regarding the hole, I thought that the object was too fragile to print a hole into, so after the casting process, holes will be drilled into the copied objects.
Here is the documentation for a small hand that I 3D printed.We were tasked with 3D printing a personal keychain using the NVBOT located in the IDeATe Fabrication Lab. The small hand was printed using grey PLA filament. Due to the specified size constraint, I printed a very small object. When it came to sanding and polishing the object, I was worried that this process would cause the smaller parts of my model to come off or fall off, which is why my printed part is not completely polished. It was also difficult to completely sand and polish the part due to its small size. This is meant to be cast into a mold, so prior to molding I will paint the object to make it more smooth. Regarding the hole, I thought that the object was too fragile to print a hole into, so after the casting process, holes will be drilled into the copied objects.
Process Photos
Submitting part for 3D printing.
Submitting part for 3D printing.
After printing, with support structure still attached.
After printing, with support structure still attached.
After printing, with support structure still attached.
After printing, with support structure still attached, human hand for size reference.
Broken off support structure.
Sanding excess support material off and trying to smooth out the print (sandpaper Grit used: 220, 1000, 1500).
Sanding excess support material off and trying to smooth out the print (sandpaper Grit used: 220, 1000, 1500).
Sanding excess support material off and trying to smooth out the print.
Process Documentation: Time-lapse of Printing
Analysis of Wall Thickness and Moldability (parting line)
Analysis of wall thickness.
Analysis of moldability along the x-axis.
Analysis of moldability along the x-axis.
Analysis of moldability along the y-axis.
Analysis of moldability along the y-axis.
Digital 3D Renderings of Final Design
Render of final design.
Render of final design.
Render of final design.
Render of final design.
Rendering from original creator.
Final Photos
Prior to Project 4
The 3D hand that I printed for Project #3 was too small. In order to make an object that could be properly sanded, I doubled the size of my previous model and 3D printed the hand again. Since this is an in-between phase, I do not have process photos, since they would be the same as the previously taken process photos in Project #3, but with an object that is scaled by 2. I have re-taken the final photos for this bigger hand.
The 3D hand that I printed for Project #3 was too small. In order to make an object that could be properly sanded, I doubled the size of my previous model and 3D printed the hand again. Since this is an in-between phase, I do not have process photos, since they would be the same as the previously taken process photos in Project #3, but with an object that is scaled by 2. I have re-taken the final photos for this bigger hand.
Sanding of Bigger Hand
Partially sanded, larger 3-D printed hand.
Partially sanded, larger 3-D printed hand.
Partially sanded, larger 3-D printed hand.
Partially sanded, larger 3-D printed hand.
Final Photos of Bigger Hand
Project 4 & Task 5
We were tasked with making a mold and copies of our original 3D printed part. I originally intended for the part line to be through the center perimeter of the hand. After multiple mold making attempts (3 attempts), I decided to make a one-part mold to see if I could create better replications of my original part. I believe the reason why my 2 part molds failed so many times was because of the intricacy of my part. My one-part mold did end up producing nice replications of my original part. In the finished cast, I decided to manually drill a hole to fulfill the keychain aspect of the project.
We were tasked with making a mold and copies of our original 3D printed part. I originally intended for the part line to be through the center perimeter of the hand. After multiple mold making attempts (3 attempts), I decided to make a one-part mold to see if I could create better replications of my original part. I believe the reason why my 2 part molds failed so many times was because of the intricacy of my part. My one-part mold did end up producing nice replications of my original part. In the finished cast, I decided to manually drill a hole to fulfill the keychain aspect of the project.
Process Photos
First attempt at making hand mold.
First part of mold mixture poured.
After 30 minutes of drying, first part of mold.
Preparing for the second part of the mold. Clay placed at the wrist of the hand in order to have a pouring spot for the resin (later).
Second part of mold mixture poured.
First attempt of making mold, original part was not securely placed while making second half of mold.
Making cast using first mold anyway to see if it would still work (flash forward, it didn’t work).
Failed first cast part using first mold.
Imperfect casted hands (from imperfect molds).
Making a one part mold.
Silicone poured for one part mold.
Cut in one part mold that allows for removal of parts.
Attempted to make molds 3 times, and the right most mold was the only mold that produced no imperfections.
First cast after using the one part mold.
Close up of first good cast.
Making a one part mold.
Final Photos
Inside view of final mold.
Outside view of final mold.
Close-up of air-bubbles in final part that could not be avoided while pouring resin.
Close-up of air-bubbles in final part that could not be avoided while pouring resin.
Final casted part with drilled hole.
Final casted part with drilled hole.
Non-sanded cast.
Non-sanded cast.
Non-sanded cast.
Final, sanded casted part, non-sanded casted part, original part.
Final, sanded casted part, non-sanded casted part, original part.
Project 5: toilet
Here is the documentation for a mockup of a toilet statue that I produced.
We were tasked with creating a 3D mockup of a product that consisted of a core and skin. For my project, I used wood as my core and modeling clay for the skin. I took a model of a toilet that I found on GrabCAD and altered it slightly so that I could have room for the skin. I also scaled down the model in order for it to be a hand-held consumer product (a toilet statue in this case).
Here is the documentation for a mockup of a toilet statue that I produced.
We were tasked with creating a 3D mockup of a product that consisted of a core and skin. For my project, I used wood as my core and modeling clay for the skin. I took a model of a toilet that I found on GrabCAD and altered it slightly so that I could have room for the skin. I also scaled down the model in order for it to be a hand-held consumer product (a toilet statue in this case).
Process Photos
Original 3D view of toilet.
Toilet modified to apply skin.
Model in Slicer. Chosen slicing method was stacked.
Laser cutting Slicer files.
One (out of 8) of the exported Slicer files, cut out of wood.
Pre-assembled parts.
12 stacked parts.
Top view of fully assembled toilet.
Side view of fully assembled toilet.
Start of applying the clay skin.
Computer & Hand Renderings
Fusion render of final design.
Fusion render of final design.
Fusion render of final design.
Drawn renderings, three different perspective views.
Final Photos
Task 4 & 6, Project 6: gears
Below is all of the documentation for the tasks and projects concerning the final project.
Below is all of the documentation for the tasks and projects concerning the final project.
Task 4 - Proposal
For my final project, I want to create a tabletop, gear pad. The gear pad will contain a variety of gears of different sizes arranged in a somewhat random, but thoughtful way. They will be arranged so that they each interlock with one another. Each gear will not be next to every other gear, but each gear will correspond with at least one other gear. When one gear is moved, the other gears will also move. The gears will be attached to a base pad that will be tabletop size.
If I find the time to add on to this project, I want to implement a sound and light element to this project. Last Fall, I partnered with another student to create a musical turntable for Introduction to Physical Computing. An ArduinoUNO, LED’s, and speakers were used to execute the sound and light element of the project. The physical structure of the turntable was created using a wooden base, an acrylic turntable that was attached to the wooden base, and cardboard cutouts to place on top of the acrylic turntable. The wheel had 3 notched dials that each emitted different tones. The entire wheel could be moved or the individual dials could be moved. If I were to add a sound and light element to this project, the same electronics and software would be used as this previous project.
To provide you with a timeline, I will first create my project with the intention of leaving out the electronic elements, but keeping them in mind. If I find enough time to work out the kinks of electronic components and account for the extra physical components in the base design of my project, I will then work on a second iteration of my final project.
I am making this project because this is something that I have been wanting to make for a while. I wanted to make this because whenever I am sitting down at my desk, I like to have something to keep my hands occupied. I want to create an artful, but useful piece that I can use to keep my hands busy. I am also interested in combining the new skills that I’ve learned with skills that I already have.
I am mainly making this project for myself. While making this project, it will make me happy by giving me something to work on that is not just math or science. After completing this project, it will keep me engaged and happy.
To be more specific, the base of the pad will be a little bigger than a sheet of paper and be laser cut from acrylic. The gears themselves will be laser cut from acrylic and wood, to mix different materials together. The gears will be attached to the base using nuts and bolts that are locked to allow for rotation. I have not yet thought of more ways to implement more fabrication methods, but hopefully this is ok and I will try hard to use some more new skills that I learned.
For my final project, I want to create a tabletop, gear pad. The gear pad will contain a variety of gears of different sizes arranged in a somewhat random, but thoughtful way. They will be arranged so that they each interlock with one another. Each gear will not be next to every other gear, but each gear will correspond with at least one other gear. When one gear is moved, the other gears will also move. The gears will be attached to a base pad that will be tabletop size.
If I find the time to add on to this project, I want to implement a sound and light element to this project. Last Fall, I partnered with another student to create a musical turntable for Introduction to Physical Computing. An ArduinoUNO, LED’s, and speakers were used to execute the sound and light element of the project. The physical structure of the turntable was created using a wooden base, an acrylic turntable that was attached to the wooden base, and cardboard cutouts to place on top of the acrylic turntable. The wheel had 3 notched dials that each emitted different tones. The entire wheel could be moved or the individual dials could be moved. If I were to add a sound and light element to this project, the same electronics and software would be used as this previous project.
To provide you with a timeline, I will first create my project with the intention of leaving out the electronic elements, but keeping them in mind. If I find enough time to work out the kinks of electronic components and account for the extra physical components in the base design of my project, I will then work on a second iteration of my final project.
I am making this project because this is something that I have been wanting to make for a while. I wanted to make this because whenever I am sitting down at my desk, I like to have something to keep my hands occupied. I want to create an artful, but useful piece that I can use to keep my hands busy. I am also interested in combining the new skills that I’ve learned with skills that I already have.
I am mainly making this project for myself. While making this project, it will make me happy by giving me something to work on that is not just math or science. After completing this project, it will keep me engaged and happy.
To be more specific, the base of the pad will be a little bigger than a sheet of paper and be laser cut from acrylic. The gears themselves will be laser cut from acrylic and wood, to mix different materials together. The gears will be attached to the base using nuts and bolts that are locked to allow for rotation. I have not yet thought of more ways to implement more fabrication methods, but hopefully this is ok and I will try hard to use some more new skills that I learned.
Task 6 - Moodboards
Here are the moodboards created for Task # 6. The objective of this task was to create two moodboards. One of the boards describes the target user, while the other board describes the final product.
Here are the moodboards created for Task # 6. The objective of this task was to create two moodboards. One of the boards describes the target user, while the other board describes the final product.
Target user moodboard - The target user is myself and the life that I lead is stressful (because of school) and since I typically sit for most of the day, I fidget around a lot.
Final product inspiration moldboard - This moodboard depicts the design and fabrication inspiration for this product. The final product was inspired by a previous project. I also was inspired by things that exhibit circular motion or rotate.
Project 6
For Project #6, I executed the project I proposed in Task #4. The product that I completed for my final project can be described as a gear pad storage box. The box is meant to be a decorative tabletop storage box. Each gear corresponds with another gear. I generated the gears using geargenerator.com and exported them to Rhino. I engraved patterns on the gears and cut out notches to add depth. I wanted to incorporate electronics into my final project, but due to the short timeline, I failed in executing so properly. I purposefully cut out the notches in order to allow light to reflect onto a photoresistor that would be placed under each gear. When the light hits the photoresistor, a speaker will sound a tone that corresponds to a gear. I actually started incorporating electronics into my final project, but was unable to get it to work properly, as shown in some of the process photos below.
For Project #6, I executed the project I proposed in Task #4. The product that I completed for my final project can be described as a gear pad storage box. The box is meant to be a decorative tabletop storage box. Each gear corresponds with another gear. I generated the gears using geargenerator.com and exported them to Rhino. I engraved patterns on the gears and cut out notches to add depth. I wanted to incorporate electronics into my final project, but due to the short timeline, I failed in executing so properly. I purposefully cut out the notches in order to allow light to reflect onto a photoresistor that would be placed under each gear. When the light hits the photoresistor, a speaker will sound a tone that corresponds to a gear. I actually started incorporating electronics into my final project, but was unable to get it to work properly, as shown in some of the process photos below.
Process Photos
Gear generation.
Preparing files for laser cutting.
Preparing files for laser cutting.
Preparing files for laser cutting.
Laser cut gears and box.
Laser cut gears and box.
Testing the fit of the bolt and trying out spinning mechanism.
Assembled top of box.
Interlocked 2 nuts to prevent self loosening.
Closeup of top of box.
Closeup of top of box.
Closeup of storage compartment that was meant to store electronics. Circles cut out for speakers.
Speakers inserted after electronic testing.
Photoresistors put into place for testing.
Attempted electronics, but failed to complete this in time.
Final Photos & Product Flyer
