Week 5 Log: The Hybrid "Zero-Glue" Enclosure

Project Status: Group Sprint | Focus: Hybrid Manufacturing (2D Laser + 3D Print) & Tolerances

The Mission: The 3-Hour Pressure Cooker

For my second group project, I had the incredible luck of teaming up with Rawan again! We already knew we made a great team, which was crucial because this week’s challenge was basically a high-speed engineering sprint.

Our target was to design and manufacture a custom box, but the rulebook was strict. We had exactly 3 hours to brainstorm the idea, design the CAD files, and finish the physical fabrication.

The Design Strategy: The Pen Holder

We took our inspiration from a unique, modern pen holder. Our strategy was to build a 5-piece assembly where the main body was laser-cut wood (fast), and only the complex curved end-cap was 3D printed (slow).

1. The 2D Laser Cut Body (Wood)

To build the main rectangular chassis without glue, we utilized male/female interlocking joints. By designing tabs and slots into the $3\text{ mm}$ wood, the pieces could be press-fit together like a puzzle.

• The Challenge: Getting the dimensions "mazbota" (perfectly dialed in) was tough! Accounting for the laser's kerf (the amount of material burned away) took some serious focus to ensure the joints were tight enough to hold without glue.

2. The 3D Printed Curve (PLA)

We designed a smooth, curved end-piece in Fusion 360 to give the box its unique shape. By keeping this part small, we minimized our print time to stay within the 3-hour deadline.

The Ultimate Challenge: The Slider Mechanism

The hardest part of the project was figuring out how to attach the 3D-printed curved cap to the 2D wooden box without cheating and using glue.

The Solution: We engineered a custom Slider Joint. Instead of trying to press-fit plastic into wood, we designed a track mechanism. The 3D printed curve was modeled with a built-in rail that perfectly matched a groove on the wooden box. The two different materials seamlessly slid and locked into one another.

Visual Log 1: The Vision vs. The Reality 

FIGURE 1: THE HYBRID ENCLOSURE LIFECYCLE

• Left (The Inspiration): The sleek, modern pen holder that sparked our initial concept.

• Middle (The Final Build): Our engineered interpretation. We adapted the curved aesthetics of the original design but completely re-engineered the mechanics to fit the strict "Zero-Glue" rule and the 3-hour time constraint.

• Right (Deployed in Action): The functional prototype in use. Here is how the slider mechanism and hybrid compartments hold up in the real world as a working desk organizer.