3D printing Dock for Wireless Charger Ublolabs
3D printing Dock for Wireless Charger Ublolabs
Model: AWC1098 (Costco version)
Model: AWC1098 (Costco version)
Embedded Files
Wireless Charger Dock
Wireless Charger Dock
There are some problems with the wireless charger.
I have to line it up exactly to get charged.
The phone is easy to fell off the charger.
It's not easy to use while charging.
I design the dock to fix those problems above and still able to use the USB-C port on the bottom.
How did I do it?
How did I do it?
The Dimension of the charger is 80mm x 80mm.
Then I have to figure out the average position of the charger coil inside all the phones.
The ideal position of the charger on the dock is 35mm above the base.
The first design was a thick block with a square cut into it that fits the charger because I didn't know how thick it was strong enough.
The first version worked fine but was too big and ugly. Also, it needed a lot of filament.
So I came up with another design that needed less filament and was nicer. It has thinner walls and base, but it is still strong enough and not easy to break.
I work for all of the phones in my house. Samsung Galaxy S10, Samsung Galaxy S20, iPhone SE, iPhone 14 Pro, and iPhone 14 Pro Max
What had I learned from this project?
What had I learned from this project?
Tangent Constraint
Tangent Arc
Mirror
Project
Tangent Constraint
Tangent Constraint
Use Tangent to make the connection of the line and the circle is much smoother.
Mirror
Mirror
Mirror the sketches so save time and accurate.
Project
Project
The Project feature is coping the Sketches from other Planes to the current Sketches Plane.
The version 2.0
The version 2.0
After speaking with my customers (classmates), they noted that the design is visually pleasing. However, they suggested that the wall should be made thicker and the base should be lengthened to prevent it from falling over.
After speaking with my customers (classmates), they noted that the design is visually pleasing. However, they suggested that the wall should be made thicker and the base should be lengthened to prevent it from falling over.
The v1.0 broke at the predicted weak point due to its 3D-printed nature, which made it composed of layers that easily broke apart at the connections.
The v1.0 broke at the predicted weak point due to its 3D-printed nature, which made it composed of layers that easily broke apart at the connections.
- The back wall is too thin. It is easy to brake.
- The base is a little short and easy to flip over.
- The holder is too thick, it's wasting filament and time to print.
Create the rim around the back wall to make it stronger.
Longer base
Thinner phone holder.
The v2.0 still had the breaking issue, adding borders didn't prove to be effective. I then decided to make the back wall thicker, but to maintain its aesthetic, I used the Loft Tool to gradually increase the thickness from the edge to the middle of the back wall, giving the illusion of a thinner wall.
The v2.0 still had the breaking issue, adding borders didn't prove to be effective. I then decided to make the back wall thicker, but to maintain its aesthetic, I used the Loft Tool to gradually increase the thickness from the edge to the middle of the back wall, giving the illusion of a thinner wall.
Conclusion
Conclusion
The V2.1 is significantly stronger with a larger base, making it more stable and preventing it from flipping over. The back wall has been thickened, resolving the breaking issue.
The V2.1 is significantly stronger with a larger base, making it more stable and preventing it from flipping over. The back wall has been thickened, resolving the breaking issue.
It also eliminates the need for support structures during printing, saving on the filament and reducing print time.
It also eliminates the need for support structures during printing, saving on the filament and reducing print time.
Manufactoring
Manufactoring
The product was tested using PLA 3D printing, but it was not strong enough for practical use. To manufacture it for commercial use, I plan to use Selective Laser Sintering technology with Nylon as the material.
Nylon 12 is a thermoplastic polymer that can be 3D printed using Fused Deposition Modeling (FDM) or Selective Laser Sintering (SLS) technology. The material is known for its good mechanical properties, high-temperature resistance, and chemical resistance. However, it is not considered a fully recyclable material. It can be recycled through a process called mechanical recycling which involves grinding, washing, and pelletizing the material, but it is not as simple as recycling other materials like plastics.
Attached is the quote from Xometry.
Measurement: 110.4mm x 90.7mm x 86.0mm | 4.35in x 3.57in x 3.39in
Process: 3D Printing
Technology: Selective Laser Sintering (SLS)
Material: Nylon 12, Color: Black-Dyed
Finish: Standard
Threads and Tapped Holes: 0
Inserts: 0
Inspection: Standard Inspection
Quote-Q74-6503-8831.pdfTo scale up production, the product must be manufactured using injection mold technology. This is because injection molding is more cost-effective for mass production compared to 3D printing. Injection molding allows for the creation of high-volume, identical parts at a lower unit cost. Additionally, injection molding can produce parts with better mechanical properties and surface finish compared to 3D printed parts. However, the cost of injection molding can be higher than 3D printing in terms of initial investment as it requires a mold to be made before the production starts. But in the long run, it would be a more cost-effective method for large scale production.
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