Final Project Journal

The design process of my project began with shaping the main concept. The initial idea was to create an automatic cat feeder that can monitor the food level inside the container. An IR sensor was added to detect whether the food amount is running low, while a buzzer works as an alert system to notify when it’s time to refill. A servo motor was used to control the release of food, allowing better management of the portions provided to the cat.

Softwares 💻

At the beginning of the design phase, I faced a lot of challenges because it wasn’t just about creating an external shape or a rough idea. The design had to fulfill the main goal of the project, which is distributing food to the pet in a smart and organized way.

I was confused between several design ideas: how the structure should look, where to place the motor and the servo, and how to route the wires without making them messy or interfering with the movement. Each of these points required a lot of time and careful thinking.

I kept comparing different designs, and every time I noticed a small flaw that could later cause a problem in operation or food refilling. That’s why I spent a lot of time researching online, reviewing existing designs, and modifying them until I finally reached what I consider a complete and functional design.

For this work, I used Fusion 360 to create detailed and precise mechanical designs. Then I used Cura to prepare the 3D printing files and make sure that all parts would come out with the correct size and accurate measurements. I also used LaserCAD to prepare some parts that could be made with laser cutting, such as the cover or the base supports.

One of the main focuses in my design was adding a middle layer inside the structure. The purpose of this layer is to organize the wires in a neat and structured way instead of leaving them tangled. This made the device look cleaner, easier to handle, and more practical for maintenance in case I needed to change or adjust the wiring later.

I also considered the importance of refilling the food container. That’s why I designed the system in a way that allows easy access to the container, so I can open the cover and refill the food quickly without the need to disassemble the entire device. This feature makes daily use much more convenient.

Now I will start explaining to you the mechanism I used and the design I implemented 

The Design🔨🏗️

I started the design by drawing the first side, which would serve as the main side of the structure. This side was created to allow me, if possible, to add the intermittent feature of the ball launcher that I already have in the complete setup.

I then made a copy of this side so that I could create the second side with the exact same dimensions. However, I modified the sketch of the second side to make it closed, since I do not need to add anything else to it at the moment

After that, I used the grounding feature to fix one of the two sides I had created. I also used the projection feature to mark the positions where the tabs of the sides would fit. I offset 3 mm from each side to account for the tab dimensions relative to the length I wanted for the back side.

I designed a simple back side in a small area to allow the bar supply cable to pass through, and created another space for the on/off switch. At this point, the back side was ready. I also made a copy of it, and of course used Paste New so that I could work on the front side.

I spent some time calculating the diameter of the feather and the circular opening to ensure it was neither too large nor too small. I also remembered to add holes for the tabs to accommodate the mid layer that would be created later

After that, I moved on to designing the bottom side, taking into account the tabs and slots that were made on each side, which will be assembled into the overall design. I also added support features to help secure the middle layer and assist in organizing the circuit wiring neatly 

Quickly, I created the top side using the same method: I copied and used Paste New from the bottom side. Then, I edited the sketch to add an opening for refilling the food container, slots for the push buttons, and finally the LCD screen 

Finally, I worked on the middle layer, which will hold the servo and the food container. I made sure this layer is slightly smaller than the top and bottom sides because it will be placed inside the box, avoiding overlaps and dimensional issues. I used the projection and joints features to ensure everything is correctly positioned, from tabs and slots to the overall placement.

I also added spaces for the servo support, tank support, and the support under the middle layer, which help the tabs and slots hold this layer securely without any problems. This layer is mounted on three sides only, leaving space at the back for wires to pass easily to the LCD screen and push buttons.

 I also added the dimensions of the supports I created, all fully customized to fit the design. I made many adjustments to achieve their final current shape. Each type of support has two pieces, except for the servo support, which has only one 

Of course, I used joints to assemble the entire structure together, along with screws and nuts. I also added the essential components that need to have room in the design before cutting the wood on the CNC machine 

The Mechanism ⚙️🦾

Steps on how to add a mechanism in Fusion 360

Video for clarification  📽️

Final look 🪶

The fabrication process of my project started with four main software tools: Fusion 360, Cura, LaserCAD and Convertio website Each tool was used in a specific stage of the process.

Softwares 💻

I began with Fusion 360 to design the model. After completing the design, I needed to convert each face and extract the outlines of every part. Using the Fusion extension, I transferred the design to LaserCAD, which allowed me to prepare the files for CNC cutting on the Malky ML64 machine. Once transferred, I adjusted the design according to the dimensions of the plywood sheets I had (30 × 50 cm), as provided by the instructor. I carefully arranged the parts on the sheet to minimize material waste.

In LaserCAD, I also added some creative touches to the external body of the structure. I chose outline images, converted them into DXF files using Convertio, and then integrated them into my design so they could be cut into the plywood as decorative elements. I set the cutting speed and power in the software, connected the machine to the laptop, and uploaded the design. The cutting process was carried out in four stages to complete the full structure.

For the Cura software, I used it to prepare and print the mechanical mechanism that formed the core of the project. I uploaded the STL file into Cura and optimized the printing orientation to save filament and time. After confirming the setup with the instructor, I exported the design as G-code and transferred it to an SD card for printing. The 3D printing was done using the Creality Ender 3 Pro, with orange PLA filament. Since I requested overnight printing 🌃🛌, the part was completed and ready to be integrated into the project.

How to Convert a Project from Fusion 360 to LaserCAD 🔃

Highlights from the cutting process of the project parts using the CNC machine🪚🪵

Potos showing the 3D printing process of both my project’s mechanism and my friend Yousef’s mechanism. Both mechanisms were printed using the overnight printing.👁️+🛝🪶

Softwares 💻

Wiring⚡🔌

Wiring Details 🪡

Inputs &  Outputs Components: 📥📤

Softwares 💻

Project Integration ⚒️️📐

During the integration phase, I carefully combined the mechanical and electronic parts of the project. Using Fusion 360’s joint feature🧩🧩, I simulated the movement of the mechanism to ensure that all the parts would work smoothly together. I also measured every component (Arduino, sensors, servo, LCD, etc.) inside Fusion 360 to make sure they could be mounted properly without interference.

After fabrication, I mounted each part step by step and solved small issues such as wire management and fitting tolerances. This process ensured that the final assembly was both functional and reliable.

Mounting 🧩🔩 

For assembling my project, I used several mounting techniques to ensure stability and proper alignment of all parts:

• Tabs and slots to interlock the plywood structure easily.🪚 

• T-slots for accurate positioning of wooden panels.

• 3mm screws and nuts to fix the main body parts together.

• Captive nuts in places where disassembly might be required.🔒 

• Cross slots and wedge joints designed in Fusion to lock parts without needing extra brackets.
  
  

These combined methods made the assembly strong, precise, and easier to manage, especially for organizing the internal wiring

I received a lot of feedback throughout the diploma, and honestly, the instructors were always available whenever we needed them. My classmates were very supportive, and everyone tried their best to help each other in any way they could.

Of course, the many suggestions and ideas we shared with each other were extremely helpful. I spent time proposing ideas and solutions, as well as working on drawing designs through practical suggestions. We also learned how to convert images into DXF files and add them to LaserCAD so that we could accurately design our projects.

We also brainstormed together to solve design problems, whether it was from someone’s suggestion or by dedicating time to work collaboratively so that everyone could complete what they needed to.

Of course, I can’t forget the journey of creating a food container using many types and forms of materials, and the general idea of how to secure it, as well as using various tools and materials. It was a journey of searching all around Zagazig to find suitable alternatives for the mechanism, and also working with the 3D-printed blade.

There are several improvements I would like to make if I had more time.

First, I want to find a solution to the issues with the Bluetooth module, as I’m sure there is a way to integrate it and allow remote control of the device.

Second, I would like to add a ball launcher, or design an alternative mechanism that can achieve the same function.

If I had the chance to redesign the project, I would also optimize the box layout to better use the available space and increase the container’s capacity compared to the current one.

Finally, I would like to add a water dispenser feature, which would make the project even more complete and practical