Fall 2021 - Fall 2022 Project Showcase

Indiana Jones Fertility Idol

This prop replica was created by Chloe Leis, one of the student employees in the lab. She printed the model out of resin, primed it with black spray enamel, and then finished it with a coating of gold leaf Rub n' Buff to give it that classic metallic look.

3D printed Automatic Coin Sorter

This 3D printed coin sorter was created by Ian Hakeman, one of the student employees in the lab. He first started with a manual coin sorter from thingiverse.com (on the left) and then 3D modeled in Fusion360 the bowl, legs, battery and switch mounts so that the coin sorter can be run by dumping coins into the bowl and switching the motor on. He also designed and laser cut the wheel that the motor spins, as well as the face plate for the storing element.

Custom Laser Cut Sign

This custom sign was made by Chiana Chuc. This was an original design created using Adobe Illustrator. The physical materials used were ¼" and ⅛" birch wood. The sign is composed of two layers. The bottom layer is thicker for stability and only has the QR code film strips engraved onto it. The QR codes are all the same and link to the "Varav Studios" Youtube channel. To make the second layer, the thinner wood was laser cut to make the border and the center objects (film camera and name). The center objects were first engraved to have a distinct color before being cut and glued onto the bottom board. This was the first sign she designed as a gift and gave it to a very happy recipient.

Laser Cut Dice Box

This tiny treasure trove was constructed by Annika Krein, but designed by shrimpcryptid on Instructables. The box is constructed by stacking and gluing together 9 slices to create a 3D shape, instead of milling the form. In this instance, ⅛" birch wood was used, which is then stained for a more pleasing color. The box holds a standard 7-piece set of 16mm dice.

It's perfect for any tabletop adventure; just the right size to keep your dice safe, and the engraving on the lid can be customized to perfectly fit your character or campaign.

To make your own, check out the link here: https://www.instructables.com/Laser-Cut-Magnetic-Dice-Boxes/

Wood and Resin Phone Case

This phone case was designed for an iPhone 12 using Fusion 360 by Toby Chappell. The materials used for the case include stabilized Buckeye Burl wood and resin and were cut on the Roland CNC Mill in the Manufacturing Lab. In addition, a flexible rubber insert was printed on the J850 and glued into the case so that the phone can pop in and out easily.

Avatar Skateboards Series

These skateboards were designed as decorations for the Manufacturing Lab created by Sesame Gaetsaloe. The skateboards were sanded then wrapped in tape before being laser engraved with the design. After engraving, Sesame used an airbrush to darken the majority of the linework and then add colour to the bending logos. Lastly, the final boards were varnished and are hung in the lab.

3D Printed Drone

This drone was designed, printed, and assembled by Tyler Lewis, first on a Prusa 3D printer then on the Markforged 3D printer for added strength in the continuous carbon fiber reinforced frame.

CRISPR Crisis Board Game

As part of their Grand Challenges Initiative (GCI) project, Kayla Anderson and Julie Tran designed this Operation-like board game that lights up and beeps when the tweezers make contact where they are not supposed to. They used the Ultimaker 3D printers for the pieces, the waterjet for the metal board, and prototype PCB board to keep the electronics compact.

Plane Business Card Holder

Using TinkerCAD to modify and piece together different files off Thingiverse, Nathan Ranaei printed and assembled a Boeing 787 business card holder on the Ultimaker 3D printers. The remixed file can be found here: https://www.thingiverse.com/thing:5501657

Stage Design

As part of the Flower Moon Festival in Spring 2022, a music festival hosted by The Collective, Charlie Molin laser cut and painted foam core flowers in the DCI Lab.

Mascot Project

This project was created by Ryan King, a Graphic Design Major for his Graphic Design I class. This is a 3D wood relief print with different 4 different layers.

The process started by creating thumbnail sketches, refining the ones he liked, then vectorizing the final piece of digital artwork. The plywood was masked, engraved and painted by hand in several layers.

Lake Tahoe Relief Carving

This relief carving of Lake Tahoe was modeled from a vector file by Ethan Slade in Fusion 360 and the toolpath was generated in Fusion 360 as well. It was then milled out of a piece of hardwood with the MDX-50. He then painted the inside blue and filled it with resin.

Apple Watch Band Holder

Modeled in Fusion 360 by Max Miller, this Apple watch band holder was milled on the Tormach CNC mill. The toolpath was generated using Fusion 360 CAM and required many iterations before the final version was created.

Slide Whistle

This slide whistle was made by Eric Chier as a final project for his Design for Manufacturing class on the MDX-50 CNC mill. Each half was cut on the rotary axis and glued together. A hand forming slide was made with the belt sander.

Upcycled Chair

These upcycled chairs were made by Charlie Molin using pallet wood and some old metal frames. The wood was cut down to size using the jigsaw and belt sander. Holes were then drilled into the wood and metal pieces using a drill press and hand drill. The wood was dyed and burnt to create the different looks.

PARROT PUPPETS

These functioning parrot puppets were made by Chloe Leis for the Chapman Student Org. Productions stage play "The Crooked Star", an original pirate musical.

Chloe used Blender to design the puppets from scratch, went through a lot of prototyping, and ended up with 3D printable skeletons that she covered with faux fur and feathers to make the birds come to life. Inside, she looped fishing line throughout the puppet so that their beaks and wings could move with a pull of a lever and their heads could swivel.

Phone Booth

This Phone Booth was a project by Lars Kahn and his friends for an independent film. Joey McWherter designed the 3D model and built it, Aly Pickett often assisted building it, Aidan Lee was big general help, and Nick George and Jules Barnard helped in painting. Using many of the power tools and hand tools in the manufacturing lab, they cut down the wood and acrylic to size and connected with screws. The sign was then laser cut and the entire box was painted.

Laser Cut Heart Box

For her laser cutter design project in her Design for Manufacturing class, Kalin Richardson designed a heart shaped box in Fusion 360 and cut it out of plywood using a living hinge technique to create the shape.

3D model miniature

Meet Blue, the star of an animation thesis by Annika Krein. Blue was sculpted in Zbrush, textured in SubstancePainter, and topologized & rigged in Maya. She was printed on the Stratasys J850.

3D Printed Trunk Light

In order to combat the challenge of finding items in his trunk in the dark, former DCI Lab student worker Ian Hakeman designed a 3D printed trunk light with a switch that tied into his Miata's battery. He went through multiple iterations in PLA for both the light mount and the fuse holder to fit in a small section of his trunk door. The final piece was printed on the Markforged with the nylon carbon fiber material to withstand the heat of his car.

His demonstration of his design process and thinking led him to win the Make-a-Thon prize for the Fabrication category!

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