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Mechanical Fabrication
Foundationally, the game is mostly mechanical, with the electronics only enhancing the autonomy of the game.
Using a combination of techniques (laser cutting and 3D printing) and materials, we constructed the main board (AutoCAD seen to right) and the control box which serve as the fundamental components for our game.
Hi-Fi_Autocad.pdfLaser Cutting
Due to the relative consistency, efficiency and precision of laser cutting, the vast majority of our mechanical elements were designed in AutoCAD and laser cut, out of either 0.25" or 0.125" MDF, cardboard and 0.094" acrylic. The accuracy of the laser cutting enabled various components to be cut separately, then assembled into their final form.
Laser_Cuts (website).pdfAutoCAD files (to left):
Top backboard - 18"x32"; 0.25" MDF
Bottom backboard - 18"x32"; 0.25" MDF
Slots (top and bottom) - 12"x24"; 0.25" MDF
Paddle fronts - 18"x32"; 0.25" MDF, Cardboard
Side boards, shape bars (top and bottom), more paddles - 18"x32"; 0.25" MDF
Acrylic (x2) - 18"x30"; 0.094" Acrylic
Control Box, Feet - 18"x32"; 0.25" MDF
Servo paddles, flaps - scraps; 0.125" MDF
One of the most time-consuming mechanical elements to create were the paddles. Their unique oblong and tapered shape was designed to avoid friction with other paddles while also providing a smooth surface along which the ball would fall. While 3D printing was an option, the prospect of failed prints and limited printer availibility led to the laser cut paddle design. Totaling to 105 paddles, they were contructed by stacking on a layer of 0.25" MDF, 5 layers of cardboard and a final layer of 0.25" MDF a 3" (0.5" diameter) dowel. These layers had to be hand glued together with a combination of wood glue and hot glue, transforming the paddle from a two-dimensional shape to a three-dimensional object, capable of deflecting and redirecting the balls.
Full_Paddle_Assembly (w knob2).mp43D Printing
While the majority of our mechanical components were laser cut, a few specfialized pieces were designed in SOLIDWORKS and 3D printed using standard PLA. Due to the risk of failure and the limited availability of 3D printers, we limited the parts that were printed to only those that required specialized design and couldn't be constructed in an alternative fashion.
SOLIDWORKS Drawings (to right):
Knobs (placed on the end of the paddles for ease of turning) - these were originally desiged to be simple hexagons, but then redesigned with small divuts to assist the children to grip them
Hourglass holder (eases attachment between the hourglasses and the 360º servo motors)
Ball (the balls used in our game needed to be a specific size to fit between the backboard and acrylic) - at 100% infill to make then dense enough to set off the limit switch at the bottom of the board
3D_Printing (website).pdfThe video above demonstrates a simplified version of the mechanical fabrication process for the main board of our game. The backboard and sides were first put together, then the paddles were contructed and inserted into the holes in the backboard. Once this was done, the servo attachments could be constructed before the top and bottom slots were inserted into place. On top of this, the acrylic would be place and secured along each edge with a small piece of MDF, a screw and a bolt. The shape bars, made from the laser cut MDF and fabric, could then be placed along the top and bottom. Finally, the 3D printed knobs were placed on top of each dowel before the entire board could be propped up with the laser cut feet.
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