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Sun Light

Final Digital Fabrication Assignment

Sun Light Overview:

  • Synthesis / Define
  • Ideation / Develop
  • Test / Implementation / Deliver
  • Reflection

    • Synthesis / Define

    Design Prompt Criteria:
  • Criteria #1: An artistic wood box with a 3D printed moveable mechanism that opens to reveals a Vitamin D light.
  • Criteria #2: Follow "Final Project" protocol as described in Assignment 7
  • Criteria #3: Technical Documentation (Bill of Materials etc...)
  • Criteria #4: Must use a combination of at least 4 techniques in your final
      • Technique #1: Moveable Parts
      Technique #2: Onshape/Fusion 360
      Technique #3: Stock Parts
      Technique #4: Laser Cutter
      Technique #5: 3D Printed
  • Learning Objective: Better understand the interconnected moving mechanisms of the 3D printed piece.

    • Ideation / Develop

    Problem: Due to lack of sunlight, millions of people suffer from Vitamin D deficiency each year.

    Promise: A LED lamp will help users provide and supplement Vitamin D for their body.

    Offering: A high powered LED light (that produces Ultraviolet B rays) encased in an artistic box.

    Prototype 1.0

  • Create a Laser Cut Press fit box (designed to hold a Vitamin D light) in mind using files for the laser cutter from Makercase
  • Use Fusion 360 to 3D Print the Moveable Iris model parts sourced from Thingiverse
  • Attach the 3D printed piece to the Laser Cut Box with stock parts like a screw

    • Prototype 2.0

  • Create my own Moveable Iris models using Fusion 360
  • Cut and raster an abstract geometric pattern with the laser cutter to match form with function
  • Explore materials types for the laser cut box

    • Test / Implementation / Deliver

    "Fail Fast. Fail Cheap." was my motto with this project.
    Utilizing online resources, I used Thingiverse and Makercase to produce a v.5 prototype identify apparent problems. This allowed me to regularly iterate through problems while simultaneously achieving Prototype 1.0 and 2.0 as described in assignment 7.

    The Instructions below describe how to convert a Thingiverse file into a useable model in Fusion 360.

    Process Step #1: After importing Thingiverse file into Fusion 360, use the "Mesh to BRep" tool convert the mesh file into a body.

    Process Step #2: Use either the "Project" or "Offset" tool to create an outline onto a new sketch.

    Filler

    Process Step #3: To create one cohesive form that can be extruded on the new sketch use "Control Point Spline" to connect each anchor point.

    Problems

    A lot of things went wrong from the laser cutter kerf loosening the press fit parts to the 3D printers have broken or the printed parts snapping.

    Considering how many things could have gone wrong, a lot was avoided.

    Many 3D Printing problems occured from misprinted pieces to thin pieces getting snapped off.

    Initial testing with the Laser Cutter ran flawlessly so I was shocked to find the intricate parts of the leaves to burn up.

    Filler

    Laser Cutter would burn through some pieces of wood while burning through similar material pieces at the same rate. (3 Speed, 100 Power, 10 Frequency)

    Solutions

    In order to solve my problems, I tested and explored different variations to create solutions that are optimized for an ideal outcome. For example, I created a custom model so that i can easily adjust the model's geometric variables and relationships.

    I learned how to create custom models in Fusion 360 then used the custom models for rapid prototyping testing the relationships using 3D printing.

    Tested variation of laser cutter setting to determine which one will cut smoothest.
    (11 Speed, 85 Power, 10 Frequency)

    Filler

    Attempted to expand the model such that the holes align with the box and could be screwed together.

    Outcome

    In the end, I was able to create and assemble Prototype 2.0 as described in assignment 7. The prototype is a wooden box that encases a LED light and is an aestheticly pleasant way to absorb the UVB rays which your body can turn into Vitamin D.

    Used glue and clamps so that the box could maintain its form while holding the weight of the light. I believe in the next iteration, I could adjust the the kerf settings to .003 to minimize this issue.

    The Mechanical Iris opens and closes manually. The button on the right can be tapped to turn on the light.

    Filler

    I used tape to protect the exposed wood from burn marks and soot stains that occur during the laser cutting process

    Reflection


    Overall this was an excellent project that pushed me to learn more about advanced digital fabrication techniques, such mechanical design, which allowed me to complete my prototype deliverables and achieve my Learning Objective as described in assignment 7.

    Areas of future research could focus on refining the UX of the Mechanical Iris so that feels comfortable to slide open. This would be done by adjusting the door material thickness as well as the

    Upon researching this topic further I could not find sufficient evidence that convinced me that LEDs lights release Ultraviolet B rays to help your body release Vitamin D. Further research would be required.

    Attribution:

    Joshua, Angel, Dhwani Vekaria, Julie Do, Peter, Andrew, Nicole, Kimberly, Cindy Feng, Corynne, helped each other out with best practices.

    Source files

    Click the Items below to acces the Source Files
  • Adding Screws to 3D Printed pieces
  • McMaster Tool Guide
  • Creative Commons - Public Domain Dedication 80MM FAN COVER IRIS STYLE by UKCD is licensed under the Creative Commons - Public Domain Dedication license.
  • Makercase
  • Free Mandala Vector Design by: Vecteezy!
  • Illustrator - Mandala
  • Fusion 360 - Iris Door
  • Fusion 360 - Iris Base
  • Fusion 360 - Iris Blade
  • Iris Gcode

    • 3D Printer Settings
    Nozzle Temp: 235 Degrees
    Platform Temp: 60 Degrees

    Laser Cutter
    Original Setting:

  • Speed = 3
  • Power = 100
  • Frequency = 10

    • Final Settings:
  • Speed = 11
  • Power = 85
  • Frequency = 10

    • Offset with .003 Kerf

    Filler

    Bill of Materials