Week 2: Make-through

• Step 1: First step that totally don't is speeding up the videos and skipping some parts to start thinking almost from scratch. (Obviously these videos are there for a reason).

• Step 2: I took me a lot to even make the box walls and lids as it has been long time since last time I used fusion 360.

• Step 3: T-slots designing is one of things you can never do without planning your steps before starting, which as expected, I tried to skip.

• Step 4: The result of me skipping the videos and even planning my designs was that I wasted 90+ minutes of my time :''(.

• Step 1:Sketch Box Walls , lid and bottom after settling Dimensions.

• Step 2: Extrude Sides and Walls with the thickness of the material you will use for fabrication, in my case it will be 3mm plywood.

• Step 3: Then we sketch screw places on lids and sides

• Step 4: Cutting through lids and walls with taking into consideration screw head sizes, thread size and screw length

• Step 5: Repeat the previous 2 steps but for nuts

• Step 6: Sketch and Extrude finger joints (they really ease the assembly process and makes the box more rigid).

This speaker design is inspired by the theme of (ROBOTS) Animation movie by Disney where every things from characters to devices and machines, have their screws, bolts and motors appearing from the outside and not hidden.

• I wanted to try using 3d printed parts to join laser cut parts as I failed in doing it in a previous time.

• So I decided to use T-slots only for the lid, 3d printed edges for joining the four faces and bottom.

• Step 1: I sketched the base on the ground plane and on an offset plane (where offset value = side height).

• Step 2: Extruding 3mm of base and sides

• Step 5: T-slots of the lid was made with same steps in the previous objective

• Step 6: 3D printed Edges were done by sketching it's top view projection then extruding each plane on it's own then cutting wholes for screws and wider ones for screw head fit.

• Step 7: For drilling wholes for electronic components mounts, we have to insert these components in our design in order to take their projections.

• Step 8: Now after placing each component in it's wanted place, we can take projection of each whole on our sides as planes then extrude cut them.

• For better look I put some finishes for wood and yellow color for printed parts, hopefully to be done after fabrication.

Now you're ready to export your STL's and DXF's and start fabrication :D.

Slicing 3d printed parts:

Using Prusca slicer, slicing process is done to export G-code files which the 3D Printer works with. Standard settings are all set (LAYER HEIGHT 0.2, NORMAL SPEED, 15% INFILL)

Laser works and RLD files exporting:

To export RLD files that the laser machine works with, we import DXF files to laser works programs and then set our settings which are set according to our wood type.

In our project we're using 3mm plywood, which it's settings are 65% power and 25% speed for cutting mode.

Fabrication process itself didn't have any obstacles, but there were some post fabricating process.

3D printing:

these extra strings was very strange to me, I thought it the designed is ruined. But then I know from FabLab specialists that it's a common issue with the wood filament.

Then final step was assembly, I had some problems with 20mm screws so I replaced them with shorter ones.

Another foolish mistake that was irreversible, that I don't know how it happened that the base didn't fit well :''(, which affected Arduino mounting .