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)

The assignment idea is to design and fabricate a mobile phone holder. I do use my mobile phone while making and creating things or when I follow a tutorial on youtube so I am so excited to create this holder.

My inspiration came from the tilt angle adjustment of my scroll saw and also the compass with angle lock.

My idea is to have a holder with the following features:

A free tilt angle (not steps) to be able to adjust it upon the viewable angle.
A rigid and solid holder to hold heavy phones without falling.
A place for the charging cable.
The holder should not block the phone camera area as it might be used as a stand for shooting.

As we learned from the first week, I have started to sketch my idea using pen and Paper:

After the sketch, I started to build a low fidelity prototype from cardboard for the holder to make sure of the sizes, the validity of the mechanism, and the look & feel.

Tool Chain

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

I used a simple craft tools to build the cardboard prototype.

Then I used Autodesk Fusion 360 to sketch the design and assemble the parts.

Used LaserWorks as a software to prepare the RLD file that will be sent to the Laser Cutting machine.

The Laser Cutter machine will be used to cut these parts.

The material will be 3 mm plywood. To be rigid and to last long.

There will be M3 screws and nuts to assemble the parts using the T-joints.

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?

1- After getting the accurate measurements from the cardboard prototype.

2- I started to design the sketches of each part on Fusion, did a fully qualified design.

3- Then I did extrude the sketch to be 2.5 D.

4- Added joints to assemble the parts and make sure it fits well.

5- Exported the sketches to DXF files to be prepared and used on the laser machine software (Laser Works).

On Laser Works,

1- I did imported all the parts.

2- fixed the scale issue by removing the extra Zero on the dimentions.

3- Remove the construction lines (some times it need to got back to Fusion 360 and remove the lines and export to DXF again.

Note: That converted the file to be not fully qualified.

4- Duplicated the needed parts Ex. the side x2 and the connector x2 the shelf parts x2.

5- Moved the parts on the design space to better allocate to lower the material wast.

6- Gave a safe space for each part.

7- I have managed to add some simple engraving to the design to make it stand out.

8- Added text on the bottom to sign my name and the maker diploma year 2022.

9- I managed to differentiate between the cutting process (in black color, speed is 15 and power is 70) and the scanning or engraving process (in Red, speed is 300 and power is 45).

10- Saved the file to .rld format to be ready for the lab fabrication visit.

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?

I went to the lab and added my RLD file to the Laser Cutter computer, I did make sure that everything is ok and downloaded the file to the machine.

On the machine control, I did set the origin, checked the focus and selected my file to track, then I did a run order.

Laser cutting done.

IMG_0159.MOV

Laster Cut the design in time-lapse

The laser cutter did the job nicely but with a challenge you'll know about it below ;)

IMG_0162.MOV

I did started to assemble the parts by using M3 Screws and nuts, also I used super glue for some of the parts. Here you go the Mobile Holder.

IMG_0195.MOV

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?

The Chair we did as practice during the mid-week session.

I did ask my Instructor (Eng. Ibrahim) about how to import a sketch from another fusion project to my current project and he did show me the way.

I have faced a scaling problem when I opened the DXF files on the laser works program and (Eng. Amany) told us that sometimes the changing between apps (Fusion & Laser Works) adds zero to the dimensions. So I did remove the Zero after locking the width & height and it worked perfectly.

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?

We did have a mid-week assignment to design a mini chair and Laser cut it. I found that the constrains lines from Fusion appeared on the Laser Works program, so we managed to remove the lines on the laser works and it worked.

Our chairs came out differently based on the design, especially the recliner part with curves also the wight center of the chairs was different so some of the chairs do not standstill.

I wanted to add the M3 screws and nuts to the Fusion design so I did a google search and found the way of inserting hardware components from McMaster-Carr Library.

Another challenge: The machine finished the laser cutting of the final file but we did realize that it didn't engrave (scan) the text that was written. So the instructor helped me for the reason that the font was so fine and with no filling so the machine didn't recognize it. We fixed this issue by doing the following:

1- Added a new color (parameter) to cut but quicker with low power so it will write the text but not powerful enough to cut it all the way.

2- Changed the other two colors output to "No" so the machine skip it and do not re-cut it again.

Final Project

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

An idea of the final project enclosure.

I have learned some skills using Fusion 360 Software and how to build parts with exact dimensions, extrude and assemble them and do the T-joint which will be used a lot in my final project. I did learn that I may need to re-run my file on the laster cutter to help the pieces to get out easily and that happens if the cut power is low or the cutting speed is high.

WOW!

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

I have learned to design on CAD software it was a dream come true. Thanks to the Maker Diploma team.

The idea of getting something out of your mind put it on paper then to cardboard and then to computer-aided design and finally fabricating it is amazing by all means.

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.

Found this amazing winning instructables about a coffee serving robot that I did learn a lot to help with my final project.

https://www.instructables.com/Rori-the-Coffee-Robot-Who-Act-on-the-Movie/

Assignment Design Files

Mobile-Holder.f3d

Mobile-Holder .rld (Ready to Laser Cut)

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