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
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