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)
A '4-Parts' mobile holder design concept
It' a very simple mobile holder and it consists of four assembled parts ( Back - Bottom - Right and Left sides)
I was keen to use multiple types of joints:
Tee slot for screw and nut joint (back and bottom joint)
Tab joint for joining the back with the two sides.
The tabs of the two sides are long enough breaking through the base bottom; thus, they work as 'seats' for model stabilization on table top.
I was inspired by the design and assembly of the enclosure of the Game Kit from week 0.
Tool Chain
Which software/machines/materials did you use in the assignment? Why?
I used Fusion 360 to design sketches, extrude and assemble the 2.5 D parts of the mobile holder
Fusion 360 Interface
I used the Laser cutter to fabricate the 2.5 D parts of the holder
El Malky ML 1390 CO2 Laser Cutter @ODC
Material: A sheet of Plywood (3 mm. th) was used to fabricate the design parts
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?
Bottom side fully defined sketch
The first step is to do a 'Fully Defined' sketches for the four parts in relevant planes
I created a new sketch, and I sketched the bottom in the XY plane with the shown dimension.
Notes:
The center lines of all sketches were constrained with the 'Fix' constrain and they turned to the green color accordingly.
All lines of the sketches were defined according to their dimensions from the 'fixed' construction lines. To make sure that your sketch is fully defined, you have to ensure that all lines of the sketch are colored in black as shown in the figures for the four parts of the mobile phone holder.
Right and left side fully defined sketch
I sketched the right and left sides in the XZ plane with the shown dimension.
Back side fully defined sketch
Finally, I sketched the back side in the YZ plane with the shown dimension.
T-slot fully defined sketch
A detailed, fully defined sketch for the T-slot with full dimensions are shown here (Left)
After completing the four sketches, they all were extruded by 3 mm. (Plywood sheet thickness)
Bottom extrude
Sides extrude
Back extrude
And here the assembly stage comes! By using the 'joint' tool and pointing at the right points for assembly.
Using 'Joint' tool to assemble objects
Back and bottom assembly
Right and Left sides assembled with Back and Bottom
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?
Saving all sketches in DXF format
Then all DXF files were imported to RD WORKS software for scaling and cutting parameters adjusting
Important Note:
All construction lines should be removed before saving to the 'U File' format otherwise these lines would be cut by the machine.
DXF files importation to RD Works
Important notes:
All construction lines should be removed before saving to the 'U File' format otherwise these lines would be cut by the machine.
Cutting Parameters: Power: 60% - Cutting Speed: 10 mm/s
All parts should be stacked altogether closely to save material while cutting
The 'U File' then saved to the flash drive to perform cutting process with the Laser Cutter
All mobile holder parts - prepared using RD Works
Total workspace area: 279 mm x 194 mm.
Construction Lines removed (ready-to-cut parts)
Setting parameters on Laser Cutter:
Navigating to find the desired file
The focus (adjusting), origin point and work space of the machine were defined as well as as the work time preview.
Time needed for cutting completion: 6 minutes and 0 seconds 😃
Focus Adjust
Work space Tracking
Laser Cutting work time preview
Parts are assembled and jointed
Mobile Holder in use !
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?
I benefited a lot from the 'optional support session'. For example, I was confused about how to save my 3D Fusion 360 design file on my laptop for a further modifications and sharing here in the journal, and luckily I was guided to use 'Export' command to save my design file in an 'f3d' format 😃
Export a 3D Fusion design file to an f3d format
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?
One of the most interesting skills I have learnt was how to 'cardboard' 😃
The first time ever to make a cardboard model was during week 0, and really I gained the confidence to make it myself in collaboration with Doaa Atef, one of my colleagues. I do remember that time how it was really challenging to make the model. However, for my preparation for the hands-on minds-on activity for week 1, I had the confidence to prepare the required tools and to make my mobile phone holder!
Besides, after my fabrication process for the mobile holder, I faced some difficulty while trying to assemble the parts, but with the kind help of Amani, one of the instructors who was at the lab during my fabrication, it was perfectly assembled as the design was originally correctly assembled in Fusion 360 and it was just a matter of plywood sheet tolerance 😃
My laser-cut phone holder fully assembled!
My first cardboard ever 😃 (upper)
My mobile holder cardboard for hands-on minds-on activity (lower)
Final Project
How can you use the skills and knowledge that you've acquired this week in your final project?
The technique of sketching, assembly of the 2.5 D extruded parts and then Laser Cutting preparation and implementation are essential to design and finalize the enclosure part of my final project. Besides, the concept of 'card boarding' is very useful for demonstrating the idea behind the project, and to communicate its features and action with target audience.
WOW!
What is the coolest thing that you've learned this week? What is something that you will never forget from this week?
During the midweek session (Wednesday), we have executed the sketching exercise of the 'Fidget spinner' where we have tried many sketching features in Fusion 360
Fidget Spinner Sketch using Fusion 360
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