Design and Fabrication

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)

We had to draw a design for the lamp we were making to get it ready for fabrication.

Tool Chain

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

Software:

Fusion 360

We used it for the 3D design

Grab cad

for downloading the components needed for the design

Laser Works

For preparing the file for laser cutting

Cura slicer

for preparing the file for 3D printing

Material:

PLA filament

M3 screws and nuts

3mm plywood board

Machines:

laser cutter( ML1390)

3D PRINTER (Prusa i3mk2)

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?

Bracket design

We designed bracket to attach all the design parts together with screws.

How it looked after cutting it

We did the same thing to the botttom

We added some fillet and material for a better user experience

We drew a scetch of the main body

We created a plane to mirror the previous feature on it

We used extrude cut to build the main part

We drew two circles to cut through the body for the screw holes

Body Design

The Base component

First, we created a component called the base and drew a sketch in it then extruded it

We mounted the Arduino, relay, and small breadboard. We drew holes for them to attach the components to the bottom.

The sides parts

we created a component called the side, then we drew a sketch of the side part in it by projecting the connection points between the base and side

Then extruded it

we copied the side parts components and used paste new option to create new components out of them

we added some rigid joints

We inserted the bracket into our main design

We attached the brackets to the design using joints.

The top component
Drew the top part and extruded it

We created a sketch to project the holes made into the bracket on the bottom to cut extrude it.

We made a circular pattern of the hole

Mounting all the components and mad necessary holes

Adding power

ON/OFF switch mounting

IR sensor mounting

Note: All parts and components are gthered together using rigid joints

The lamp parts
We drew a sketch of the lamp top part

We drew part to conect the two wooden parts with the hollogen lamp.

Extruded it. Added some fillet for a better experience.

Extuded it. Adding somr fillet.

Mounting the hallogen bulb.

Drew the other part and added some joints.

Adding appearence to show the material we're using.

Diffuser Design

Hassan's final project was the inspiration, but his approach to drawing was a little difficult.

So,came up with the idea of drawing a 3D truncated octahedron first, then drawing the faces on it. Drew the 3D truncated octahedron using this video tutorial
https://youtu.be/6nt1frnahsE
However, did some calculations and changed the dimensions as needed.

Then started to project the faces and draw the slots for joints and Extrude it

Draw the geometric patterns and extrude it on only one square and hexagon faces

Project , draw and extrude the joints

Made a circular patterns to increase the numbers of joints

Add it to the lamp

Final results

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?

Using dxf for laser add-on, we exported the faces to dxf for laser cutting.
We exported stl files for brackets using Save as Mesh

For Laser cutting we used laser works with the parameters:

speed: 30, Power: 55

For 3D printing, we used Cura Slicer. with parameters:

infill: 15 || Grams: 15 g || Layer height: 0.2

Fabrication

Parts of the body

Parts of the diffuser

Assembly

Mounting components (Arduino, relay module, and breadboard) on the Base.

Assembled the six sides with the base using the brackets, screws, and nuts.

Mounting LDR module, Dc connector, and ON/OFF switch

Assembled the sides with the base and others sides using the brackets

Assembled the halogen lamp with the 3D printed joint, the top part, and the two parts of the lamp

Assembled the two parts of the lamp with the top part using t-slots and screws and nuts

Assembled the captive nut brackets with the sides

Assembled the top side with the sides using captives nut brackets, screws and nuts

Assembling the parts of the diffuser, it was meant to be joined using CrossFit but needed to use super glue during the process.

Overcoming Challenges

What kinds of challenges or problems did you face while doing the assignment, tutorials, or exercises? How did you solve them? Did you ask for help from an instructor or peer? Please provide a link to the tutorial or article that you used to solve your problem (if any)

We faced a problem that the tabs of the lamp didn't fit in the to part. As the nut took a space we didn't consider during design, We had to redesign this part.

add the T-slot on the two sides instead of the middle.

There was another problem during designing the corners. This was the first design. after printing it. We found out that screws would intersect with each other. We had to redesign it.

Old design

New design

Final Project

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

We knew the dimensions of our project, the limitations, and insights about how our components would fit together

WOW!

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

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.

Assignment Design Files

STL files

Fusion file

DXF files

Page updated

Report abuse