Fabrication Process

The physical parts of my smart device box were fabricated using laser cutting.
The fabrication was divided into three stages: design, file preparation, and cutting.

1. Design Preparation

• I first designed all parts of the box in Fusion 360, including:
  
  

  • Top and Bottom Plates: 220 mm × 180 mm

  • Right and Left Walls: 180 mm × 160 mm

  • Front and Back Walls: 220 mm × 165 mm

  • Separating Wall: to divide the lower (components) and upper (gift) compartments.
    
    

• I then exported the flat side drawings as .DXF files, which are compatible with laser cutting software.
  
  

2. Laser Cutting Setup

• I used RDWorks to import my .DXF files.

• Inside RDWorks, I set the following parameters for wood cutting:

• for cutting:

  • Power: Cut adjusted based on wood thickness (50 for 3 mm plywood).

  • Speed: 30

• for scanning :

   Power: 330

  Speed: 25

• for speed cut :

 Power: 400

  Speed: 12

• I placed all box panels on the digital workbed to fit the wooden sheet size.
  
  

3. Fabrication Process

• The wooden sheet was fixed on the laser cutter bed.

• The laser cutter traced the cutting paths and cut out each panel accurately.

• After cutting, I removed the wooden pieces, cleaned edges, and checked for accuracy.

• The parts were then assembled into the box, with the separating wall placed inside.

• The lower room was prepared for electronics installation, while the upper room remained as the gift space.

Electronic Circuit Description

The smart device is controlled by an Arduino UNO which acts as the brain of the system. The circuit integrates input components (Bluetooth signals) with action/output components (DC motors + servo). All components work together to create a controllable smart box that can move and respond to user commands.

1. Input Components

• Bluetooth Module (HC-05/HC-06):
  
  

  • Connected to the Arduino via TX/RX pins.

  • Receives commands sent from a smartphone app (such as Arduino BlueControl).

  • Each button on the app corresponds to a character (F, B, L, R, S) that the Arduino reads.

2. Action/Output Components

• DC Motors :

  • Controlled through the L298N motor driver.

  • Enable pins (ENA, ENB) control motor speed using PWM.

  • Direction pins (IN1–IN4) determine the movement (forward, backward, left, right, stop).
    
    

• Servo Motor:

  • Connected to pin 10.

  • Can be used to open/close a lid or move a small mechanism inside the box.

  • Starts at a neutral 90° position in the code.

3. Motor Driver (L298N)

• Functions as the interface between the Arduino and motors.
  
  

• Inputs: IN1–IN4, ENA, ENB (from Arduino).

• Outputs: Two DC motors connected to OUT1–OUT4.

• Allows forward/backward control and speed adjustment using PWM.
  
  

4. Circuit Integration (How It Works Together)

1. The Bluetooth module receives a command from the phone app.

2. Arduino reads the incoming character:
   
   

   • ‘F’ → forward() → both motors rotate forward.

   • ‘B’ → backward() → both motors rotate backward.

   • ‘L’ → left() → left motor reverses, right motor moves forward.

   • ‘R’ → right() → left motor forward, right motor reverses.

   • ‘S’ → stop() → both motors stop.
     
     

3. Arduino sends HIGH/LOW signals to L298N motor driver to execute the movement.

4. Servo motor can be triggered for specific actions (e.g., lid opening).

 Circuit Diagram

Sources of Inspiration and Support

• Omar: helped me debug my code and correct errors.

• YouTube tutorial: I watched videos to understand the code of moving car the ultrasonic sensor with the servo.

• AI-Assisted (ChatGPT):
  
  

  • I used ChatGPT to make sure that everything was going correctly in my code.

🔹 Feedback & Peer Contributions

• Omar:
  
  

  • Helped me debug my Arduino code and explained some mistakes I had.

  • His feedback improved the stability of my program.
    
    

• Abdel Rahman:
  
  

  • Gave me advice when my Arduino didn’t work with the battery.

  • He explained that the battery needed charging after being unused for a long time.
    
    

• Asmaa:
  
  

  • Helped me use the driller safely and provided me with colors and tools to finish the box.
    
    

• Eman:
  
  

  • Helped me when I needed to cut the circle for the wheel and later when I decided to add a switch.
    
    

• Yassin:
  
  

  • Always followed up with me to check on my progress and encouraged me to keep going.
    
    

💡 How I Helped My Peers

• I shared my Fusion 360 bracket design with them so they could reuse it.

• I explained some of the steps I learned in RDWorks for laser cutting.

• I supported classmates in assembling their projects when they needed an extra hand.

Support:

Yassin😌was always checking on my progress, asking for updates, and motivating me throughout the project. His encouragement made me more determined to complete the project.