Week 3 - 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 is to design a pen and pencil holder model that may rest on a flat surface (Tabletop).

I care about this idea because it's some new level of complexity, and I can imagine anything and try to make it real.

The idea of shields and Arrows inspired me, and I want to turn the pen holder bedside as the main idea.

Tool Chain

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

I used Ultimaker-Cura software to edit and prepare the file for the printing stage – and I will use the 3D printing machine (Prusa i3 MK2) to print it, and the material is PLA filament.

I used Laser work software to edit and prepare the file for the Cutting stage – and I will use the Laser cutter machine to Shape it, and the material is 3mm plywood board.

I used fusion 360 to design the models I will use in my project.

I used cardboard to make a mobile holder prototype because I can easily shape it, and it is affordable around me.

Prusa i3 MK2

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?

I-Pen Holder Design

Step (1): I started to draw the shield shape. I used many different ways until I found the easy one, which was the arc tool.

Step (2): I extruded the Shield sketch by 5mm thickness and I added circles with a 3m diameter for M3 bolts, which will be used to connect the Bracket together after fabrication, and another circle with a 9m diameter for pens

Step (3): I began to find out how to anchor this shield to the ground, and I decided to use the captive nut, so I designed a new one with specific diminutions.

Step (4): I extruded the Bracket sketch by 5mm thickness and I added a circle with a 3m diameter for M3 bolts, which will be used to connect the Bracket & Shield & Ground together after fabrication.

Step (5): I started by sketching the main compartment, so, I started by creating the two mirrored sides.

T-slots were added with the right dimensions to the sketch to be used in connecting parts together.

Step (6): I assembled the parts together to create the big box

Step (7): creating the base bottom & create slots to add T slot connections to connect all parts with the base.

Step (8): then I created the small box ( the coin box)

Step (9): After that, I created a full assembly & attaching all parts together to have the final product.

Step (10): Then, I exported all parts to DXF files to prepare it for laser cutting machine, I used DXF for laser cutting plugin to export sketches from forms automatically.

Then, I arrange them for laser cutting.

Step (11): Then, I saved the Bracket as a mesh and opened it In cura to adjust the setting

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-Laser Cutting

I adjusted the setting of the laser cutter machine to 30 speed and 55 power and I opened the .rld file, then named the files & downloaded them to the machine.

After that I set the origin point of cutting & tracked the design space frame, then I started the cutting process which took about 4 min to finish the design.

II-3D Printing

I saved the bracket as mesh and opened it in cura to adjust the setting to 10 Infill with 215 degrees in printing temperature and 0.3 layer height without any support because I don’t need it, I loaded the .gcode file that has been sliced by Cura from the SD card,

then I selected the file from the printer & start the printing process, the print took about 16 min to finish the design.

III-Assembling design

After all the parts were ready, I assembled all parts together at their exact locations, then I used different M3 bolts to connect all parts & bolts had different lengths depending on the thickness of layers of wood connected together.

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)

The big challenge was the arrangement of steps, and this took a lot of time to experiment with which structure was the best. I passed it by the try-and-error process.

Also, I spent a lot of time making the shield a fully defined shape, and I needed to remember how to create unreal lines to use the mirror tool.

I asked Amany and Adel, and they gave me the answer.

Also, the challenge of exporting Dfx file. Every time I got the same error, I asked Nada to help with this problem.

I solved this problem ( fusion Bug) by trying many different technics, like restarting the program and selecting other parts, and I chose the part again, and it worked.

The DFX Export Error

Final Project

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

This week I gained the ability to make an idea from scratch, and I trained to find solutions and the way I can arrange the different processes to reach my goals.

Also, I gained the ability to how I can anchor different parts from different materials.

WOW!

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

The coolest thing is it's okay to ask others for help.

I will always remember the importance of an unreal line to make a mirror.

Laser cutter Machine

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.

This week in the hands-on activity, I made a phone holder prototype with an amplifier – tried for the first time to make a 3D box with 2D parts.

Assignment Design Files

bracket pro

DFX Parts

Fusion 360 project

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