ccbc capstone project pinball 0

ccbc capstone project pinball

For our capstone project in ccbc we made a collaborative pinball machine, we had to include all of the tools we used in the past project, such as the laser cutter, 3d printer, and cnc mill. We each divided up the parts of the machine, and began the process of designing, and fabricating them.

I was tasked with creating the skeleton of the pinball machine, and also one of the obstacles on the machine that was 3d printed. To create the design for the body, I used Inkscape, the body itself was made out of eighth inch wood, and cut on the laser cutter. During the first few cuts we had problems with the sight on the laser, and had to adjust it a few times before successfully cutting the piece. The front piece was the first to be cut followed by the bottom, and sides. All together there were six pieces needed to create the body, because we each made a part to the pinball machine, communication was key. Unfortunately we did have to re fabricate a few parts due to measurements being incorrect.

After the body was created we began glueing the pieces together using wood glue, making sure to leave space for the installation of the flipper mechanism that sat on the inside of the machine. After the body of the machine was finished, all that was left was to create the obstacles. I created an obstacle containing two 3d printed parts that had a rubber band stretched between them, letting the ball bounce off when it would hit them. To create the pieces I used fusion 360, which we used in the past for other 3d printed projects in the past.

Once all of the obstacles were created, we glued them onto the board using an adhesive that is very effective on 3d prints. Once the machine was fully assembled it was time to decorate. I created a vine that went along the side of the machine, and had three leaves sticking out that each had a number on them. In theory if you hit the ball hard enough to reach one of the leaves whatever number was on the leaf you would count that to your points. The markers we used bled a small bit on the wood, and made it difficult to create a solid design.

The hardest part of this project was incorporating all of the tools we used, we relied heavily on the laser cutter, and 3d printer, but were unsure of how to use the cnc mill. Thankfully in the end we were able to find a way to use it. The best part of creating this project, was getting more experience with the laser cutter, and seeing all of our pieces come together into one project.

 

Below are a few photos of the process starting with the initial sketches, and mapping, onto the beginning stages of the fabrication of the body, and the final touches.

 

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Laser cut Handheld maze 0

Laser cut Handheld maze

For the laser cut maze prompt, I created a maze which was shaped like a fish. The goal of this maze was to make your way from the eyes, to the mouth of the fish.

The initial design was created on Inkscape, an open source vector based graphic design software, that we used for our laser cutting project. from there it was sent to a google drive. Once we upload it to the drive, it is opened on the computer we use for the laser. From there it is downloaded, and imported into illustrator and exported as a dxf. We use a program called rabbit laser that we then import the dxf file into. After that, all that was left is to change the speed, and power settings based on the material you cut. You also have to adjust the laser cutter by calibrating the Z axis, and positioning your material. In this case two different materials were used, eighth inch wood, and acrylic.

The maze is created in three parts. The first is the base of the maze, that has engraved points where the inside walls of the maze will sit. The second is the walls of the maze which overlap the engravings that show where to place them. The final piece of the maze is the acrylic sheet that sits on top, this keep the ball from falling out, and provides a transparent cover. It is assembled using glue, a few nuts, and bolts. A few of the challenges I faced while creating this design, were creating the walls, making sure to keep even spacing for the ball bearing to fit through, and also keeping it challenging.

One thing I have learned from this project is how to better use Inkscape, and the laser cutter, when using the laser cutter you have to pay careful attention to your speed, and heat settings, before beginning a cut. I also learned what materials are bad for the laser, such as PVC, and which materials can cause fires if not cut properly, an example being cardboard. One thing I would do differently next time, would be to better my design and make the maze even more challenging.

below are a few photos from the process, starting with the initial sketches, to working in Inkscape, and finally the cut product.

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working with the CNC mill Mancala board 0

working with the CNC mill Mancala board

For our first time using the cnc mill (carvey), we were tasked with designing, and fabricating a mancala board. A mancala board is a part to a game, in which you play against another person, and take turns moving small stone, or marbles to score points. We each made half of a board so that we are able to take our macalas, and put them together to play.

When making the mancala boards we used fusion 360, a 3d design software that we had use previously but for 3d printed projects. After our initial design was created, we learned how to use the manufacturing tools in fusion 360, this helps make our design ready for the carvey, by creating the paths it will follow when cutting.

Unfortunately my first attempt at the mancala board did not work with the manufacture tools in fusion 360. I then remade the design, and it worked fine, I am still unsure why it did not work the first time. The manufacture options in fusion are sometimes confusion to work with, thankfully after this project I feel comfortable in preparing a file for the carvey. After exporting the completed model, we uploaded them to the google drive, and prepared the carvey.

Preparing the carvey includes putting on the bit or chute, and securing your material. Once the cut is finished we would vacuum and clean the machine to ready it for the next cut. We learned why it is important to properly clean the machine after each project, for example if saw dust is left in large quantities in the machine, it can compact under the chute and knock it off course. Creating the mancala board was fairly easy, the hardest part was using the manufacture options in fusion, sometimes it takes a while to actually make the paths work correctly. If I were to do this again, next time I would probably try and customize the mancala board more, maybe make the board itself a different shape.

These photos are from another side project that I worked one after the mancala board, it was suppose to be a teacup cutout that could be used as a fridge magnet, or decoration. Unfortunately the design did not work with the mapping tools for the carvey. Originally the edges were filleted in the original design which made it look much better, after realizing it wouldn’t work, I tried simplifying the design like the one shown below.

                                                   

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CCBC Lego mini figure project 0

CCBC Lego mini figure project

                  Our third project we were given during the course was to design, create, and print a fully functional lego figurine. We were given a regular lego mini-figure, and told to measure, and recreate it, because lego minifigures are so small, we had to double our measurements.

One of the hardest parts of making the legoman, was creating the waist. The design was a challenge, because it contained many odd shapes, and sizes. It was also difficult to get the measurements correct so it would fit well with the rest of the figure, as it had to connect with three separate parts. The easiest part of making the legoman were the hands. The design process was simple, and required only two sketches to create. The hands were the only part I was able to create, and print successfully in one try.

During this project I had practice using calipers, a tool used for measuring, that has four metal pieces called jaws, that slide up and down the tool. The larger are used for measuring external dimensions of an object, while the smaller are used to measure internal dimensions. The smaller jaws came in handy many times throughout this project, such as times when measuring the inside of the torso. I also had practice in using fusion 360, matter control the slicing software we use for the flashforge printer.

The lego brick, and the legoman project, has helped me better understand fusion because of the many tools, and ways you have to manipulate the shapes in fusion to create your project. There are a variety of tools in fusion, the ones I used the most in this project were the, loft, fillet, shell, offset plane, and ruler tool. Many of these tools, such as, loft, fillet, and shell, are used to distort, or change geometry. The other tools are used when working with the plane in fusion 360, for example the loft tool allows you to connect two sketches, by creating a physical object between the two selected planes. Another important skill I learned was how to account for tolerance on a 3d printer when making parts that have to join together.

During the fabrication process of the lego man I printed five legs, three waists, three heads, four arms, and two hands. To get the pieces fitting together some solutions I used to fix the parts were, resizing the object, remaking part of the piece, and checking my measurements. My favorite part of this project was testing if the pieces would fit together, it was very exciting seeing the legoman completed!

Below are a few images showing the design process in fusion 360 such as the begging sketches starting to take shape, the print inside of the slicing software, and also the finished product.


  

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CCBC Lego brick 0

CCBC Lego brick

Making a functional lego brick was the second design challenge we were tasked with creating in fusion360, after making the set of dice. We were each given a lego brick that we would use to measure. In this case I was given a 3×2 brick. Once we printed the bricks we would test them by trying to attach them to a regular lego, after that we would adjust the design accordingly and retry.

Out of five versions of the lego bricks, I was successful in getting one to work. During the process of creating these bricks, the hardest part was staying consistent with sizes. This project was perfect for learning how to take measurements, be precise, and account for tolerance on a 3d printer. The tolerance on the printer we used, affected the printed product. Tolerance refers to how much the original design measurements are changed due to a number of ways the printer runs. The way the printer extrudes filament, and creates the layers is one of the ways. For example, if you intended to make a square that had the dimension 10.00 mm by 10.00mm, you may not end up with those exact measurement after it prints. Instead you may have a square that was 10.20mm by 10.20mm. This may not seem like much but when trying to piece small components together, this can sometimes greatly affect the way it will fit. It’s nearly impossible to print an object with the exact dimensions is your design. Thankfully there are ways you can test, and adjust your design to fit the printer you use.

To measure the legos we used digital calipers, which came in handy when measuring the distance of the circles on top of the lego. Designing the initial lego shape was the easiest part, the bricks are made of basic geometry, mostly being just a rectangle and a few circles. because of this very few tools in fusion360 were needed.

If I were to try and make more lego bricks in the future I would make sure to test the tolerance on a printer first, and maybe make different shaped legos. Below are a few notes i made while making the brick.

Version 1 lego

  • None of the parts worked.
  • Circles on top are to big, and same with bottom.
  • Changed size of circles.

Version 2 lego

  • Top circles worked but were a bit loose
  • Bottom did not work
  • Changed size of bottom and made top circles a bit bigger

Version 3 lego

  • Nothing worked
  • Circles are to big and bottom is to loose
  • Made circles same size as V2 and remeasured the bottom

Version 4

  • Top to loose
  • Bottom works

Version 5

  • Works!!

Bellow are a few images of process.

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FabSlam Project 0

FabSlam Project

For FabSlam this year, our challenge was to build a weather proof/protectant bike helmet. First we started planning, and idea sharing for the helmet. Then started to put our ideas together. One thing we decided on making, that was the main and hardest part of our helmet was the googles. It took many prototypes to finally get the googles to work. Also we put a fabric in between the shell and the padding that would keep the rain out of the helmet. We mostly shared jobs when we needed to so if someone had trouble with the website one of the teammates would help. I mostly worked on the 3d printed parts of the project i did a little work on the website too.

first prototype:                              prototype fabric:

         

final project:

 

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