Week 2- Journal

Ideation

Tell us about your assignment's idea for this week. Why do you care about this idea? What inspired you? (Please include images or links to sources of inspiration)

Welcome to WEEK 2!

Well, in week 2, we had to go throughout many processes through a long trip for all the week.

First of all, I took the first steps in 2D sketches but how could I do that?

I first must make 2D parts but using cardboard, so it was an interesting exercise to go in more depth with Hands-on, Minds-on activity to build a model of a simple 2D mobile phone holder using cardboard along with other tools such as glue gun, scissor, ruler for adjusting dimensions and a pencil.

So, I got the finished model for my attempt at the pictures shown as we can see. It was a daring activity to take the first steps on your own without any familiarization, and I was glad to see my result for this cardboard phone holder. I guess others might like it too, right?

Then, I tried to access the Fusion 360 tool/software to learn how to use it to get 2D sketches and extrude them into 2.5D parts and finally assemble these parts for different purposes.

So, I downloaded Fusion 360 and got acquainted with its fundamental’s parameters and features through simple models like sketching a car and started working more so that I could sketch a Fidget Spinner in real dimensions like the image we have below. I only did the first steps of drawing the parts and extruding them into 2D parts. There was no need at this level to do any assembly.

Next, I customized it by adding a yellow theme. I liked the end result I got.

Source for Fidget Spinner with True Measurement Dimensions

Wardrobe model.mp4

Next, I got to the assembly stage and what a great approach it took to see the parts sketched in its final body linked together by a simple technique in Fusion 360 called assembly.

For example, I sketched whole parts for a real wardrobe and assembled to get the final body and have a chance to customize it by adding some changes that I want to have in my wardrobe in case I have one like it.

You can check it out from the video I uploaded, and you will be able to be familiar with the process you need to go through to get to the final body in the following pic.

The next step I took was to build a model of a rocking chair using Fusion 360.

So, I started, as usual, by sketching dimensions for each part, extruding them in 2D and assembling the parts to get the final body in 2.5D as we can see in the following pic.

Back to the last stop this week, I had the assignment of designing a model of a simple mobile phone holder that could rest on a flat surface using Fusion 360, saving it as a DXF file, uploading it to the LaserWorks software and fabricating it with a Laser Cutting machine.

I will make more elaborative regarding the fabricated phone holder process in the following questions. Stay amazed!

Tool Chain

Which software/machines/materials did you use in the assignment? Why?

Week 2 i call it the Week of Fusion 360, if you can call it that.

So, all week progress has been through the Fusion 360 tool/software as it helped sketch and assemble the 2D designs to get the final structure in 2.5D.

Initially, I downloaded it, got acquainted with its basic parameters and features that enable me to sketch 2D parts, extrude them into 2.5D parts and finally assemble these parts for variety of purposes.

Let me not miss it was a great chance to personalize any model by changing the appearance to any type of wood if the model is to be made on a laser cutting machine and there are certainly a lot of other looks like plastic and glass. It depends on the type of the model we are working on and the methodology for which it will be used.

Accordingly, I used Fusion 360 software to design the Mobile Phone Holder model, saved the final design file in DXF format, and uploaded it to LaserWorks program to set the required orientations and other parameters such as power and speed to be performed on the device to be able to estimate the required time and material cost.

Regarding machine and materials, I made the model on a laser cutting machine using a 50cm x 30cm plywood sheet as the material.

Laser Cutting machine

LaserWorks software

Design/Preparation Process

Explain the design and/or preparation process of your assignment. How did you use the tool or software to design and/or prepare your assignment before fabrication/implementation?

Initially, I searched on Google to pick up a model for the mobile phone holder that I would like to design and manufacture. Second, I started with Fusion 360 software to sketch in 2D the needed parts for the phone holder, extrude them to 2.5D, assemble them together and give it a personalized look by adding a wood texture to visualize the post-fabrication finish on a laser cutting machine.

So back in Fusion 360, I first sketched in 2D the face, base, top, bottom, and sides, then extruded them into new components in 2.5D and threaded the new components together across the assembly parameter and got the final body for the phone holder after adding new appearance to a wood type material where it would be Fabricate the model on a laser cutting machine on a 50cm x 30cm sheet of plywood material.

I made a magnificent simple video of whole steps I followed, if you want to play it and get familiar with how to make a phone holder on a Laser Cutting machine using a sheet of plywood material it will be interesting!

Phone Holder Design process_Fusion 360.mp4

Mobile Phone Holder design on Fusion 360 software

Top & Back View in Fully Defined Sketch

Base View in Fully Defined Sketch

Side View in Fully Defined Sketch

Face View in Fully Defined Sketch

Development/Implementation Process

Explain the development/implementation process of your assignment. How did you use the machine/tool to manufacture or implement the design of your assignment?

Oh, it was like a war day to me!

The design of the phone holder is simulated of ancient Islamic art where the wooden decoration or the popular type is the “Mashrabiya”.

First, I needed to prepare the design file in DXF format from Fusion 360, then upload it to LaserWorks to make final settings/preparations and download it as a G-code to the computer connected to the laser cutting machine and start the manufacturing process at scanning of 300 mm/s speed, 25 as a power and cutting of 30 mm/s speed and 65 as a power.

I had first to use the arrow keys to move the cutting gadget (machine head) to the top left corner of the machine, then put in a good sheet of plywood material of 500 mm x 300 mm, check the machine focus by pressing the Pulse button for less than a second, pressing Origin to set the effective cutting area and making sure the design fits perfectly, then I moved the machine like it’s cutting a rectangular piece of wood that can contain my design size but without emitting a laser. Next step I pressed file and selected the design file I named and finally I clicked RUN and closed the laser cutter lid door due to safety rules.

Therefore, one of the adventures was to design a phone holder that includes this decoration and assemble it after the laser machine was manufactured.

Accordingly, there were some challenges during the manufacturing and installation process that I will explain in the following questions. Stay informed!

I kept an outlet for the charging cord so the holder would be more applicable for other purposes too!

Phone Holder Fabrication.mp4

Fabrication process

20210805_143609.mp4

Design model manufacture on a slab of plywood material

Community of Learning

Did you ask for feedback? What are the ideas that others have contributed or suggested? What was someone else’s idea that you built upon? How did you help your peers? How did your peers help you?

Certainly, I asked for feedback from the Lab specialist about the design of the sketches prior to the manufacturing process and it was a valuable advice I followed to improve my sketches to adjust the dimensions of the finished parts to be workable to be attached together in an easy way.

Fortunately, thanks to the help of my peers, they shared with me some ideas for assembling and debugging the fabricated dimensional parts.

We were a great team working collaboratively together.

Overcoming Challenges

When you got stuck, what/who did you turn to? At what point did you have to pause to research or learn more before moving on? What are some mistakes, pitfalls, or challenges that others can avoid if they were doing this assignment?

It was hard on me to just think about the probability of faults after many trials of sketches and ideas of designing the model, so I kept asking for feedback/advice with my colleagues and the lab specialist too.

I had a moment of not doing anything and just a keep be calm to be calm and focus as I did not sleep well, so I had a support from my peers to Fit parts together and detect any faults may be resulted

It was hard for me just to think of probability of faults after so many trials with sketches and ideas for designing the model, so I kept following with feedback/advice with my colleagues and the lab specialist as well.

I had a moment of doing nothing and was calm to maintain focus as I didn't sleep well so I got support from my colleagues to fit the parts together and figure out any bugs that might result to deal with them.

So yeah, I did find some dimensional flaws after manufacturing due to an error in the sketch’s dimensions of the base stand and would have preferred to have it corrected by Fusion 360 and try to fabricate it again and I did it and it is finally working!

Dimensionally defective parts "Corrected"

Defective parts in terms of dimensions "not corrected"

Unfortunately, I did not have enough time to adjust the wrong dimensions on this part as the plate material left no space for the manufacture of another part.

Final Project

How can you use the skills and knowledge that you've acquired this week in your final project?

I believe that learning how to draw/design on Fusion 360 and fabricate model parts with a machine like Laser Cutter by adjusting settings with LaserWorks software drives progress to getting ready to advance in design and implementation of the graduation project journey!

WOW!

What is the coolest thing that you've learned this week? What is something that you will never forget from this week?

Try and try and try! This could be the most I fell into it and guess what? It works and is making more progress than I expected!

Trails is a highly skilled gadget that I've learned this week and in all the past weeks, and I think it will make more progress in the coming weeks as well.

That is what I figured out from my work this week while designing and fabricating the mobile phone holder during a lot of attempts with the Fusion 360 program, LaserWorks software and the laser cutting machine.

I can say this .. Trial is like a long and challenging journey that needs patience and focus.

Also, the coolest thing was “From Prototype to Product”, an extra-session i attended throughout this week, diving a look into the Tangible (or Hardware) Product Life Cycle starting from the Prototyping Phase (Designing/Thought’s journey) which divides into Low-Fidelity and High Fidelity or Minimum viable product (MVP), and passing into the production phase, and types of products.

It was valuable information to share with us focusing on examples of some activities in our maker Diploma, so it was a magnificent session to share thoughts/discussion with others.

Weekly Digest [OPTIONAL]

Tell us about any other cool things that you've made this week: in the Hands-on activity, tutorial examples, exercises, or any other cool mini-project that you tried out aside from the assignment.

Title of Media

Assignment Design Files

Mobile Phone Holder Files

Fidget Spinner Files

Wardrobe Files

Rocking Chair Files

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