Week 3- Journal

Idea for this week’s assignment:
I want to design and create a mobile holder combined with a pencil/pen organizer. The goal is to have a neat, functional space where I can keep my phone and all my writing tools together.

Why I care about this idea:
I often enjoy creating creative lettering and drawings while watching or listening to my favorite podcasts. However, I can never find a proper spot for my pens and pencils, and their clutter on my desk feels distracting. Having them organized in one place, alongside my phone, will make my workspace feel cleaner, more comfortable, and more inspiring.

What inspired me:
My inspiration comes from my daily habits and the frustration I feel when I can’t find the right pen quickly. I’ve also been inspired by minimalist desk organizer designs I’ve seen online, which combine functionality and aesthetics.

Design and Preparation Process:

1. Draw the Faces of the Pen Holder
   
   

   • Started by drawing rectangles for each face of the pen holder.
     
     

   • Designed the T-slot shape and position.
     
     

   • Created puzzle-like connectors on the edges so the faces could interlock without extra fasteners.
     
     

   • For two faces, cut the top edge into the puzzle shape; for the other two, cut the bottom edge into points for the base connection.
     
     

2. Create the Base of the Holder
   
   

   • Designed the base piece to fit the puzzle joints from the faces.
     
     

   • Added space for the nut so it could be fixed securely.

Laser Cutter

• Preparing the Material:
  
  

  • Placed the wood sheet on the laser cutting machine.
    
    

  • Used supports to keep the sheet stable and prevent movement.
    
    

• Adjusting the Focus:
  
  

  • Set the laser focus to avoid noise and ensure precision.
    
    

• Setting the Origin Point:
  
  

  • Clicked on "Box" to manually position the node at the desired starting point.
    
    

  • Selected "Origin" to lock the starting point for the laser cut.
    
    

• Starting the Machine:
  
  

  • Clicked "Start" to begin the cutting and engraving process.
    
    

• Retrieving the Final Part:
  
  

  • Opened the machine and removed the part after the cutting, speed cut, and engraving were complete.
    
    

3D Printer

• Preparing the File:
  
  

  • Configured all printing parameters in Ultimaker Cura (e.g., infill density, support settings).
    
    

  • Exported the G-code file and uploaded it to an SD card.
    
    

• Starting the Printer:
  
  

  • Inserted the SD card into the 3D printer.
    
    

  • Powered on the machine and selected the desired file.
    
    

• Launching the Print:
  
  

  • Clicked "Start" to initiate the printing process.
    
    

• Monitoring the Process:
  
  

  • Observed the printer’s performance to ensure smooth operation and quality output.

Bracket Dimensions: 

Before 3D printing the bracket, I sought feedback on the nut space and circle dimensions. A peer suggested increasing the nut space extrude height from 2.64 mm to 2.8 mm and the circle diameter to 3.4 mm to account for PLA shrinkage during cooling. These adjustments worked perfectly, ensuring proper fits without force. In return, I shared my design file and explained my puzzle-joint method to peers working on similar projects.

Challenge:
While preparing to 3D print the bracket, I encountered uncertainty about the nut space height and circle diameter dimensions. I was concerned they might be too tight due to PLA shrinkage after cooling, which could lead to poor fit or stress during assembly. At this point, I paused the printing process to seek advice from a peer with more experience in 3D printing tolerances.

Solution:
Based on their suggestion, I adjusted the nut space extrude height from 2.64 mm to 2.8 mm and increased the circle diameter to 3.4 mm. These small but critical changes ensured a proper fit without requiring force, accounting for the slight shrinkage of PLA. The print was successful on the first attempt. I then shared both my design file and the puzzle-joint method I used with peers working on similar assemblies.

Lessons Learned:
This experience taught me the importance of verifying tolerances before printing and not hesitating to ask for input. A common pitfall for others might be underestimating material shrinkage or relying too heavily on theoretical measurements. Taking time to research or consult someone can prevent wasted time and material.

Challenge:
During my initial test prints, I used tree supports thinking they would be more efficient and provide better support for overhangs in my bracket design. However, I quickly realized that tree supports consumed significantly more filament than expected and were difficult to remove cleanly, often leaving behind rough surfaces or damaging small features.

Solution:
After discussing the issue with a peer and researching best practices for support structures, I knew that I should change to normal (linear) supports if needed. These used less material, were much easier to remove, and left a cleaner surface finish on the bracket. The final prints were more efficient, cleaner, and required less post-processing.

Lessons Learned:
Choosing the wrong type of support can waste material and time, especially for simple geometries that don't require complex support structures. I recommend that others assess the geometry first and start with normal supports unless there’s a specific need for tree-style ones. Testing and small-scale trials before a full print can help avoid these kinds of missteps.

This week, I learned how to use the "Joint" feature from the Assembly workspace in Fusion 360 to connect parts of the Game Kit. This skill is very useful for my final project because it will help me design and assemble the entire project digitally. By using joints, I can accurately position each component, visualize how the parts fit together, and ensure everything aligns properly before physically building it. This will save time, reduce errors, and make the installation process much smoother. 

The coolest thing I learned this week was how to create a fully defined sketch for each part and then join them together using the “Joint” feature. I also understood how each part connects to the others, which made the assembly process smooth. This was my first time completing a project with minimal edits from my instructor, and it worked perfectly—the final product assembled well and functioned as intended.