AIR COMPRESSOR

This project involved the design of a compact, belt-driven air compressor assembly. The unit features an injection-molded front cover, a sheet metal housing, and a fully enclosed internal mechanism including a motor, piston, crankshaft, and pulley system. Emphasis was placed on manufacturability, clean mechanical integration, and modern industrial aesthetics. Prototyping was done using 3D printed PLA and machined components, with final designs prepared for scalable production methods.

COMPONENTS

An air compressor assembly consists of a system of interconnected components designed to compress and deliver pressurized air for various applications. Key components typically include: Motor, Crankshaft, Connecting Rod, Piston and Cylinder, Check Valve and T-Joint.

Exploded View of Assembly

Belt-driven pulley system powered by a DC motor, converting rotary motion to drive the piston assembly.

Piston & Valve Mechanism that compresses air, featuring a connecting rod, crank, and check valve for one-way flow.

This component is designed as a structural mounting frame for the air compressor assembly. It is manufactured from injection-molded abs plastic.

PLA spacer designed to elevate and align the injection-molded compressor frame above a sheet metal housing. Provides accurate standoff height and secure mounting.

A DC motor operates with a two-wire connection, supplying all drive power through these wires.

Round rocker switches are AC-rated components that are also suitable for low-voltage DC applications.

ASSEMBLY

Sheet Metal Enclosure

Formed from 5052-H32 aluminum sheet and bent on a press brake. Chosen for its excellent formability and corrosion resistance.

Injection-Molded Front Cover

Designed for injection molding in ABS, this front cover was 3D printed in PLA for prototyping. Features include functional port openings, integrated bosses, and a contoured form aligned with final production intent.

PHOTOS

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