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Final Product: Done and Ready to be wired with the help of maintenance

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Final Product: Done and Ready to be wired with the help of maintenance

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The plywood came in and we started working by laser cutting all the letters to their according 1:1 size. Then we started planning to cut the plywood into the shape of the sign, and we also cut the holes for the lightbulbs. After cutting, we painted all the letters blue and the sign itself fully white. We glued it together and assembled all the lightbulb components, as well as screwing the relays and the programmable circuit board to the actual sign, so that wiring can then be planned by either us or maintenance, but most likely the latter since they need to figure out how the circuit will connect to power up on the ceiling wall above the Tech Deck.

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The final prototype was 1:1 with the actual size of the sign and it actualised the real shape while using cardboard.

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Inspirations derived from retro style lit up signs

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Inspirations derived from retro style lit up signs

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Circuit Board for programmable sequence of light bulbs

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Circuit Board for programmable sequence of light bulbs

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The other aspect of the project was to configure a programmable circuit to make lightbulbs follow a certain sequence, one that represents the lights chasing each other, imitating the retro signs. We tested this on a separate board with a limited amount of lightbulbs and with the help of Mr Filip. We had to consider different aspects and solve different challenges, as our first circuit board stopped working due to issues with the current being too high and the voltage not regulated correctly. Finally, we figured out all the details and we used two transformers - one for the circuit, one for the lightbulbs. We also applied relays that only gave 1A of the current to each set of LED light bulbs, which made sure they didn't blew up.

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The small scale prototype serves the purpose of seeing how the idea would actually work out and would it be aesthetically pleasing. Here we laser cut the sign from cardboard and the letters from plywood, and after gluing and using LED string lights, we can see the results.

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The final version used the same design as the one in step 5, but improvements were made in accordance to the critique made in class - the metal hook was hot glued to the bottom of the cylinder so that it's more stable; medical tape was used around in order to make it more comfortable overall to the ear skin. The design successfully stayed in the air and the audio quality is not affected.

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Design from Fusion 360: Half-hollow cylinder connected to the ear hook, which was swept across a sketch made using a point fit spline

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The final design that was settled on was made on Fusion, with a connecting piece to the stem of the AirPod, a hook on the bottom and a slightly cut ear hook from the actual printed version. The flexible PLA allowed for the hook to curve around the ear with no problem, and its stability was ensured with it connecting to the hook.

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Many designs were printed out for testing. some working and others not, assessing the comfortability of this type of ear hook and also how effective it actually is for staying in the ear successfully.

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The earhook was measured for the sizes of an AirPod Pro, with an estimate of its actual length, which was then roughly created to imitate the prototype with a flexible cleaning tube.

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Kim, J.; Ban, K.; Im, Y.; Jung, E.S. Hook Type Wearable Device Based on User Discomfort. J. Ergon. Soc. Korea 2017, 36, 765–776. [Google Scholar]

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The next step was to identify different ear hook models that have been designed previously. Their lengths and adjustability proved to assess similar comforts to all types of ears, which made the process of choosing what design to sketch first more flexible. Also various lengths of the different parts had been conceived, which made it easier when measuring correctly.

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The first step to designing this ear hook was to look at the anthropometrics of the ear. The average lengths between the hole, connection, and pinna are showed here. These were taken into consideration when deciding the height of the ear hook itself.