Design Module Specifications

Technologies

In the mechanical design module you will need to use the following techniques to manufacture an enclosure for your sensor board:

• 3D printing

• Waterjet cutting

• Laser cutting

• Milling

• Turning

When making your enclosure all techniques will have to be employed.

Specs

The enclosure needs to be low weight and attached to the human body.

The enclosed battery will need to be charged without dismantling the enclosure.

The wireless communication will need to function after enclosing the circuit board.

The circuit board will need to be protected and held in place.

Software

You will need software to design and manufacture your parts:

CAD: Solidworks or OnShape or Autocad

3D Printer Slicer

ProtoMax Design and Make

Laser Cutter imports dxf files. If you use Inkscape, export in inches.

Raw Materials

Materials available for your design are (see pics below)

• 6061 Aluminum Bar: Diameter: 3, 1.8 , 1.25, 1, 0.88, 0.75. 0.5, 0.37 inch

• 6061 Aluminum Flat: 1.5, 0.5, 0.38, 0.25, 0.13

• 303 Stainless Steel Sheet: 0.03

• 303 Stainless Steel Rod: 0.37 inch

• Copper Sheet: 0.26, 0.63 inch

• Bronze Rod: Diamter 1.25, 0.5 inch

• Bronze Sheet: 0.08 inch

• Acylic: 1/4 or 1/8 inch

• Plolycarb sheet: 1/16 inch

• Rubber sheet: 1/16, 1/32 inch

• HDPEF: 1 inch

• Delrin Sheet: 1/4 inch

• Glass slides, regular microscopy slides, BK7

• 3D printer filament: PLA & Flex

• Machined metric screws:

  • M3: Phillips 12, 10 mm long

  • M3: Nut, Nylon Lock Nut

  • M3: Hex Countersink: 4, 6, 10, 12, 16, 20 mm long

  • M3: Hex Socket, 20, 16, 12, 10 mm long

  • M2: Hex Countersink: 18, 12, 10, 8 mm long

  • M2: Button Head: 4, 6, 10, 16 mm long

  • M2: Nut and Nylong Lock Nut

  • M2.5: Button Head 4mm long

• Your own materials such as fabrics, leather:

The housing can not be made with anything else than materials shown in the images below unless you provide raw materials for the whole course before fabrication design is due (drop off at Urs Utzinger, 2618 E Mable, 85716).

Numbers for battery: 30 x 16 x 6.1 mm, charger board 27.8 (USB port sticking out additional 0.7)x 17.1 x 2.5-3.5 mm

End mills and their diameter. If the recess or slit is the diameter of and endmill its easier to make it.

Drills (o) and Reamers (*):

Metric

* 1, *o 1.5, *o 2, *o 2.5, *o 3, o 3.2, *o 3.5, *o 4, *o 4.5, *o 5, *o 5.5, *o 6, *o 6.5, * 7, * 7.5, *o 8, * 8.5, * 9, * 9.5, *o 10, * 10.5, * 11, * 11.5, * 12, * 12.5, * 13

Fractional

*o 1/16, o 3/64, *o 5/64, *o 3/32, * 7/64, *o 1/8, *o 9/64, *o 5/32, *o 11/64, *o 3/16, * 13/64, *o 7/32, *o 15/64, *o 1/4, * 17/64, *o 9/32, *o 19/64, *o 5/16, *o 21/64, * 11/32, *o 23/64, *o 3/8, * 25/64, * 13/32, * 27/64, * 7/16, * 29/64, * 15/32, * 31/64, *o 1/2,

Tap and Die for threads