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The first challenged was to create a penholder for 9-10 pens, which were 7.00mm in diameter, and the following size restrictions had to be met:

Max height of model = 130.00mm

Corner fillets= 4.0mm

Internal shell = 5.0mm

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This is the final rendered version of the penholder. The idea was to create a simplistic and basic design, which was developed using different tools in Fusion. I started with figuring out the necessary dimensions of the shape, so as to match the challenge requirements and created the prototype drawing upon which the model was extruded and modified. I also wanted to create miniature holes throughout the shape, as most inspiration penholders had that feature, but upon exploring the different tools and patterns in Fusion, I settled on a more unique characteristic around the outer layer of the shape, which was created using the circular pattern tool.

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The penholder was printed in a minimized scale 3D model, where it seemed to have no issues with both the shape and the appearance on the outer layer, which was somewhat surprising as I thought it would be too detailed for such a small object and there would be no point in prolonging the process for a small feature.

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This challenge was based around the idea of creating a Headphone Stand, that had meet the following requirements:

For over the ear headphones

Free standing

Max height = 210mm

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This was the first developed prototype for the headphone stand, the idea was to create a hexagonal shape which would hold the headphones spread apart. While a good concept, after being 3D printed the design was too wide and would cause damage to the headphones if used, which was an issue we had considered in the process, but at this stage could not figure out how to shrink the hexagonal shape in width, while still maintaining the original idea.

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After addressing the issues with the version 1 design, we changed the overall shape of the structure in order to fix the problem with the width, and also filleted more edges to create a better aesthetic appeal, which was somewhat lacking in the initial design. The issue of this version, were the too thin legs holding it up and the scale of the design which needed to be increased in order to hold the headphones properly.

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In the final version, some small modifications were made, such as adding more stable legs to the shape and increasing the height. The issue upon the first print of this design was the deficient height and the inside curve of the top, which couldn't be printed in the intended way, and required us to try to make some changes to the shape, however we were not fully successful in that, and therefore only changed the height.

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The objective of this challenge was to create a handmade 2in1 tealight and match holder, using a 90mmx50mm wood block while utilizing the tools in the workshop!!!

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(Before engraving)

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The first step was to measure and mark out a 15mm x 37mm rectangular shape for the match holder, using a square tool and applying the previously learned reference angle skills.

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After marking out the area to be cut out, I started to cut along the lines using a saw, switching between a smaller one in the beginning when penetrating the wood, and then a bigger one to finish the cut in a more efficient and precise way. While cutting the block of wood was secured using a wood vise clamp. I made multiple cuts along the top width of the marked area and then using a mallet tool fully extracted the wood, creating the necessary shape for the match holder. The malleating process did not go as smoothly and resulted in some imperfections in the model, but they were not detrimental to the overall shape or function of the block and were mostly fixed using a rough block of sanding paper directly after that.

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After molding the wood block into the necessary shape for the tealight and match holder, the full model was sanded using different grades of paper and completed with a very delicate sanding paper to give the model a smooth finish.

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After cutting out the rectangular shape, the next task was to measure out the exact spot of the circular hole, which would serve as the tea light holder. This was done using a basic ruler and was then cut out using the pillar drill.

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This is our initial design sketch, containing all neccesary measurements.

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The first step of the building process was to measure and cut out each individual piece of the caddy. Some challenges we faced here were due to the kerf of different saws that were used. We started with the thinnest kerf and found some success in doing that, however the precision was later further improved by using the jig saw in order to cut out bigger pieces of the set. It created some inconsistencies, but the importance of the cut being straight overweighed that of minimal precision errors.

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After cutting all pieces, they were sanded using a machine sander in order to remove the yellow paint and add aesthetic appeal using the base wood pattern on the outside

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We also made a change from our initial idea by cutting out the side panels in triangular shapes at the top, in order to add more aesthetic appeal

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Our initial design for the long divider did not account for the middle dividers, so we had to measure and cut out another one, which fit our constrictions.

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As seen in the picture, the middle divider accounted for the vertical dividers to be placed on its sides, rather than inside it, which was a calculation error in the initial stage

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The new middle divider provided enough space for the vertical dividers to be placed between it using a cutout system, similar to the previous project of building a cardboard chair. It also worth mentioning that it was produced from leftovers in the initial cutting stage, and therefore required no extra materials.

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After cutting out all pieces, we used a simple drill to make holes and then use screws to assemble the final caddy. It was a very quick and effective process. However, although minimal, certain inconsistencies arising from, as previously mentioned, the kerf of the saw, create some asymmetry in the final product but were not detrimental to its look and definitely not its function.

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Upon screwing all parts together, the outside of the caddy was thinly sanded multiple times, achieving a smooth finish.

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The bottle caddy has 6 slots for bottles

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I used this youtube video to learn how to use the flange tool

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Fusion 360 - Sheet Metal Flange Tutorial

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After the first prototype was succesfully printed, I made some adjustments by adding another piece at the front of the box

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What are your personal interests?

What physical items do you enjoy playing with?

What are some of your favourite memories from Elementary School?

How can we signify these memories using a physical object?

What is something you will keep for a long time?

Do you want it to include a message?

What material would you like it to be?

Do you want it to include a name, or names of your friends?

What represents your learning experience in elementary school?

How can we represent our school in this design?

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This is the final version of Kenshin's design (on the front), he also wanted initials of his friends added at the bottonm

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The football was created using shapes and mirror/reflections in illustrator

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I created this design by tracing a real image of a mclaren, as well as adding some refinments using shapes in ai

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This owl was created using shapes and symmetry tools in illustrator and was one of the most challenging parts of the designs, but once I got the hang of it I was able to complete it efficiently and found ease with creating other illustratioins without needing to trace everythging

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These are cases where I set the wrong cut or engraving lines, or my shapes didnt connect well which caused these misprints, but through them I learned how do complete it properly

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These are small versions of the 3d print ideas I had for Kenshin, as I didn't want to waste material, because i wasnt sure he would like it, the first (orange) came out with some issues on the text which were fixed in the second (yellow)

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These were the final first draft of Alec's designs, they came out well after the first failed attempts, alec choose the one with the football along with the 3d printed one which will both be developed further

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Final drafts of kenshin's designs, which used the same illustration but different shapes, Kenshin chose the one with text and requested some further additions like engraving on the back

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This is the first draft of the 3d football, created using emboss and pattern tools in fussion, still waiting to be printed

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This is the base, shaped like an owl for kenshin's design

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This is the other one that Alec wanted, with a change only to the name speelling from the previous prototype

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Final product of the 3d football, came out well from the first print

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The final version of kenshin's laser engraved keychain, the only change was adding the initials of his best friends on the bottom