Assisting others by Sathia Bali

Why is it needed?

sathiabali — 2019-01-11 07:08:13 UTC

My client regularly travels for multiple days due to business trips, his phone is the easiest way of contacting client’s and working while traveling, the issue is that to be able to do so he needs a power bank because his phone which consumes energy quite rapidly due to the constant use. This product isn’t necessarily a fundamental need but it’s a way people can facilitate and improve their own standard of traveling by creating a more space efficient and innovative design of a phone case containing an incorporated power bank, a magnet with an apposite box designed to contain AirPods which will come with an insulator to avoid the risk of damaging the phone.

Power bank

sathiabali — 2019-01-15 01:12:23 UTC

This product is a power bank, its function is to provide a mobile extra electricity power source when traveling, it allows to completely recharge your phone from 3 to 4 times. This is a really common tool used when traveling, normally used to charge phones and tables. This model of power bank like many others is quite good for traveling because it’s really narrow as it’s width is relatively small compared to its length. Anyways this product isn’t the best for maneuverability because although it’s quite space efficient it’s still an extra object that you would need to carry around with an addition of a cable. In terms of feature that are a variety of

There are a few feature that I might consider adding on my final design:
- USB plug used to attach the charging wire
- Android charging plug (micro USB) to charge the power bank
- Narrowness
- Lights to show the battery percentage left

Phone holder

sathiabali — 2019-01-15 01:21:23 UTC

This product is a phone holder with the function of providing a support for the customer when holding their phone. It has a really original system of attachment to the phone which is efficiently keeping it together. This product can be broken down in three main parts, the edges that attach to the phone, the base and the apposite ring shaped feature where the finger is meant to be put on. This product is made out of some kind of elastic and flexible plastic which allows the extension of the product. The features I find clever and interesting to include in my own design is the way the phone cover sticks to the back of the phone also the material used is quite interesting because it allows the cover to stay elastic while keeping it strong.

There are a few things that I’m considering on adding to my final design:
- Attachment system to the phone
- Elastic materia

Pop socket phone cover

sathiabali — 2019-01-15 01:24:28 UTC

This product is a phone case with a pop socket attached to it, a pop socket is a rounded shaped phone case extension that allows people to put their fingers around it by allowing people to have more grip when holding the phone. It’s also really space efficient because it can compress into a smaller shape which is a feature that I would really like to include in my design because a specification that I’ve set to the product is to be space efficient. The phone case is a normal case made out of silicone and the pop socket is made out of plastic because it doesn't conduct electricity well (it is an electric insulator) and has little friction so you can push the plug in easily, Plastics are cheap, they are easily formed, cast, and assembled.

There are a few things that I’m considering on adding to my final design:
-Plastic insulator
-Grabbingfacilitation

Head Set box

sathiabali — 2019-01-15 01:25:35 UTC

This is a headset box which is used to expose them in shops, the purpose of this box is to appositely stop the headset from moving and getting tangled, it also has the purpose of protecting the object from getting damaged in case of fall or any type of hit because the material around the headset absorbs most of the impact since it’s made out of soft, compressible and slightly elastic material. I really like the way this is designed because it perfectly suits the shape of the headset.

There are a few things that I would like to add to my final design:
-material used to make the inner of the box
-the way the headset is folded in

Phone cover

sathiabali — 2019-01-15 01:42:18 UTC

This last product is a simple phone case, more specifically silicone phone case with a specific themed design which pictures Valentino Rossi a famous name that relates to the motorcycling industry. In this way the producer has limited target market of this product to people that relate to the specific theme of argument presented in the design of the case. The design of the pictures is transferred to the cover through a process called Spot UV Printing which allows to print images and designs on mobile phones covers. (Mobile cases) In this process, a layer of paint is applied on the surface of the phone cover and exposed to ultraviolet light. (Mobile cases) In terms of features this phone has just the basic necessary one such apposite camera, earphones and charging holes with the appropriate measurements. there’s also an interesting way they’ve designed the side volume and shut down buttons coverage which allows to cover them without compromising the functionality of them.

There are a few simple and efficient features that this product has that I would like to integrate in my design:
- Specific designs, to limit the target market and not risk to fall into banality and unoriginality.
- apposite holes for the charger, earphones and camera on the back.
- silicone cover

MLA

sathiabali — 2019-01-15 01:45:13 UTC

Burgess, Genevieve. “What Are Those Round Things on the Back of People's Phones?” Pajiba, Pajiba, 29 Jan. 2018, www.pajiba.com/miscellaneous/what-are-those-round-things-on-the-back-of-peoples-phones-.php.
Mobilecases. “The Manufacturing Process of Different Mobile Phone Covers.” Mobile Cases HQ, 20 Feb. 2017, mobilecaseshq.com/how-different-material-mobile-phone-covers-are-manufactured/.
“Impact Resistant.” Curbell Plastics, www.curbellplastics.com/Research-Solutions/Applications/Impact-Resistant.
“Thin Magnets.” EBay, www.ebay.com/bhp/thin-magnets.
“Silc Pig™, Concentrated and Fluorescent Color Pigments for Silicone.” Smooth-On, Inc., www.smooth-on.com/product-line/silc-pig/.
“Thermoforming, An Alternative to Injection Molding | CW Thomas.” CWThomas, www.cwthomas.com/thermoforming/.

Analysis

sathiabali — 2019-01-15 02:18:50 UTC

Client: Duty frees, phone cases shops, traveling shops
Target Audience: Travelers
User: Lorenzo Bali

Problem 1 : traveling with a power bank in your hands is really not comfortable and functional so my idea was to create a phone case that can hold the power bank so that the amount of objects that he will need to carry is reduced to one, making traveling much more functional.
Problem 2 : A big part of traveling especially in long trips when you don’t have much to do for example on airplanes is entertainment, more specifically musical entertainment which in public places requires earphones of headphones to not sound pollute the environment for other people. After a survey I’ve concluded that many people have issues losing their earphones or airpods and my product will include an attached magnetified apposite box for the AirPods which will prevent the customer from losing them and it will also save the customer from having to carry the although small spacing occupying AirPods box.

Need: My target audience needs a product that can efficiently take use of space and include a power bank incorporated in the phone case as well as a magnified AirPods box which will help the customer to stay organized. It’s important to stay organized and be space efficient when traveling because it avoids the risk of losing objects and it facilitates the mobility.

Material

sathiabali — 2019-01-15 05:19:07 UTC

-What materials are phone cases usually made out of?

Source type: Secondary
Possible source: mobilecaseshq.com/how-different-material-mobile-phone-covers-are-manufactured/.
Priority: 4
Qualitative

-What’s the most resistant material for falls?

Source type: Secondary
Possible source: CurbellPlastics.com
Priority: 5
Qualitative

-What’s the thinnest magnet I could get?

Source type: Secondary
Possible source:https://www.ebay.com/bhp/thin-magnets
Priority: 3
Quantitative and qualitative

-What material can function as insulators for magnets?

Source type: Primary
Possible source: Design Teachers
Priority: 5
Qualitative

-What materials are available at SSIS?

Source type: Primary
Possible source: Design Teachers
Priority: 5
Quantitative

-What colored silicone can I be provided of?

Source type: Secondary
Possible source: www.smooth-on.com/product-line/silc-pig/.
Priority: 1
Qualitative

Equipment

sathiabali — 2019-01-15 05:19:33 UTC

-What equipment is used to make phone cases?

Source type: Primary
Possible source: mobilecaseshq.com/how-different-material-mobile-phone-covers-are-manufactured/.
Priority: 4
Qualitative

-What equipment is available at SSIS?

Source type: Secondary
Possible source: Design Teachers
Priority: 4
Qualitative

-What alternatives are there to a Mold Machine (silicone covers) ?

Source type: Secondary
Possible source: www.cwthomas.com/thermoforming/.
Priority: 5
Qualitative

- What equipment is used to paint designs on the covers?

Source type: Secondary
Possible source: mobilecaseshq.com/how-different-material-mobile-phone-covers-are-manufactured/.
Priority: 4
Qualitative

Time management

sathiabali — 2019-01-15 05:19:45 UTC

-How much time will the creation of this design will take?

Source type: Secondary
Possible source: Youtube
Priority: 2
Quantitative

-How long does the Silicone cases manufacturing process take?

Source type: Secondary
Possible source: http://www.madehow.com/Volume-6/Silicon.html
Priority: 2
Quantitative

-How long does the wooden cases manufacturing process take?

Source type: Secondary
Possible source: http://www.dcifurn.com/about/manufacturing-process
Priority: 2
Quantitative

-How long does the leather cases manufacturing process take?

Source type: Secondary
Possible source: https://www.leatherfor.us/en/leather/37-0-The-production.html
Priority: 2
Quantitative

Manufacture

sathiabali — 2019-01-15 05:24:26 UTC

-What are the different types of manufactures to make phone case?

Source type: Secondary
Possible source: mobilecaseshq.com/how-different-material-mobile-phone-covers-are-manufactured/.
Priority: 5
Qualitative

-What are the different steps of phone cases manufacture?

Source type: Secondary
Possible source: mobilecaseshq.com/how-different-material-mobile-phone-covers-are-manufactured/.
Priority: 4
Qualitative

-What are the most important steps of manufacturing a phone case?

Source type: Secondary
Possible source: 
https://www.youtube.com/watch?v=B_QkiCfZGLE
or
https://www.youtube.com/watch?v=oNScirdZDTo
or
https://www.youtube.com/watch?v=G6bhGTZo8ME
Priority: 4
Qualitative

-What manufacturing processes are available at SSIS?

Source type: Primary
Possible source: Design Teachers
Priority: 5
Qualitative

-What is the most suitable manufacturing process out of the ones available at school to make a prototype of a phone case?

Source type: Primary
Possible source: Design Teachers
Priority: 4
Qualitative

Aesthetics

sathiabali — 2019-01-16 02:18:13 UTC

My product must have a curved smooth surface and it’s going to be located at the back of the phone, the attachment system is going to develop at the corners of the phone. The cable used to charge the phone will have to be no longer than 10 cm other wise it will negatively impact on the ergonomic look of the product. The AirPods box is going to be placed on top of the power bank section which is attached to the phone and it’s all going to be covered by a second layer of plastic.

Understandable

sathiabali — 2019-01-16 02:19:34 UTC

In this design there are multiple features included in one product, the challenge will be to keep the design simple and understandable for the customers.
The product must have a printed instruction guide.

Long lasting (Durable)

sathiabali — 2019-01-16 02:19:43 UTC

The product will need have to be made out of ABS plastic because it has outstanding impact resistance.
https://www.curbellplastics.com/Research-Solutions/Applications/Impact-Resistant
The product must be durable and resistant to all kind of forces, tension, pressure etc...

Environmentally friendly

sathiabali — 2019-01-16 02:20:48 UTC

The product must be made out of ABS plastic.The product will not be wooden manufactured because it’s not Eco unfriendly but it will be made out of plastic which although requires oil (finite source) it doesn’t damage the environment as much

Manufacture

sathiabali — 2019-01-16 02:21:00 UTC

I will create the product by making a custom-designed machine known as an injection mold.
I will make it with a mold base crafted from several chromium steel bars that are merged together into a block.

A mold maker is used to shape the metal mold base into the desired shape. Holes are drilled into the mold for cooling fluids. Finally, once the mold base attains the correct design, it is smoothed and polished.
Once it is ready, I will pour t hold plastic he injection mold. After that, cooling fluids are poured through the holes to help the plastic harden and cool. The plastic, which has now become hard, is then popped out of the mold, polished is ready.

mobilecaseshq.com/how-different-material-mobile-phone-covers-are-manufactured/.

Cost

sathiabali — 2019-01-16 02:21:08 UTC

The product will cost around 10 dollars per model because the cost of the material is of $ 19.98 per kg in summation to 2 dollars for the manufacture which includes the electricity used for the machines and the time consumption. So in total I will sell the product for around USD 13.

Customer

sathiabali — 2019-01-16 02:21:12 UTC

My customer must be users of iPhone 6s and the target market are travels as my product will have to facilitate and make traveling more enjoyable

Size

sathiabali — 2019-01-16 02:21:17 UTC

The product must be of:
width: 83 to 85 mm
length: 160 to 170 mm
height: 25 to 45 mm

Safety

sathiabali — 2019-01-16 02:21:26 UTC

The product will include an insulator for the magnetic AirPods box and it will also have to be sanded to remove and thorns

Function

sathiabali — 2019-01-16 02:21:34 UTC

The product must allow the customer to charge his phone device and hold AirPods.
The product must also work as a phone case and perfectly suit the phone.

Summary of research

sathiabali — 2019-01-16 03:07:59 UTC

TIME MANAGEMENT:

- The silicone cases manufacturing process is a very quick efficient process, that typically averages 30 seconds, with an organic material or high consistency silicone, the average cycle time to get a part made is around six or more minutes. Peroxide cured materials take even longer, commonly around nine minutes.

-This process takes 12-40 hours depending on the type of wood, the diameter of the block, and other factors.

MATERIALS:

-Phone cases are usually made out of silicone, wood

-The most impact resistant materials are:

ABS, Outstanding impact resistant low cost plastic, easy to machine, and thermoform
CAB, Clear, flexible plastic sheet with excellent drape and blister forming characteristics.
ECTFE, Fluoropolymer with outstanding mechanical properties and dimensional stability.
ETFE, Plastic material with excellent mechanical strength, stiffness, and abrasion resistance.
EVA, Soft, flexible copolymer with low-temperature toughness, and stress-crack resistance.
FEP, Flexible fluoropolymer with outstanding chemical resistance and electrical properties.

- 4 Neodymium magnets are the thinnest Round Discs 5mm x 0.25mm N52, Super Thin! 0.25 5. Strength: N52.

-The most recommended magnetic insulators are wood, Plexiglas, styrofoam, brass, copper, aluminum, steel, iron, paper, stainless steel, and any other materials you think may work

-The materials available at SSIS are ABS plastics, various types of wood, steel and few other types of metal.

-Silicone is normally white but it can be customized to any pigment of any color.

EQUIPMENT:

-The equipment used to create phone cases consists on:
- CNC machine
- mold maker
- compression mold machine
- Spot UV Printing to print images and designs

- At SSIS we are provided:

-Saw machines
-3 printers
-Drills
-Hammers
-Saws
-Screwdrivers
-Sanding machines
-Vacuum former
-Furnace

- Alternatives to Mold Machines are:

-Vacuum Forming. Large MAAC rotary thermoforming machine. Vacuum forming is one of the most widely-used methods of thermoforming, a common alternative to injection molding.
- Pressure Forming. New MAAC pressure forming machine.
- Thermoforming and Injection Molding

- To paint designs or picture on phone covers, Spot UV is most commonly used

MANUFACTURE:

- The three types of phone case manufacturings are leather, silicone and wood.

-The manufacturing processes available at SSIS are wood workings, Plastic modeling which divides into 3D modeling and another method which melts the plastic, there’s also provided metal and textile manufacturing available since we have a furnace and a sawing machine for textile materials.

-The most suitable process to make a prototype of a phone case is 3D modeling,

PROTOTYPING:

-a first or preliminary version of a device or vehicle from which other forms are developed

-a prototype is generally used to evaluate a new design to enhance precision by system analysts and users. Prototyping serves to provide specifications for a real, working system rather than a theoretical one.

sathiabali — 2019-01-23 03:01:22 UTC

Priorities in a scale of 1 to 5,
5 being urgent and more important and 1 not important and not urgent

Prototyping

sathiabali — 2019-01-23 03:12:14 UTC

-What is a prototype?

Source type: Secondary
Possible source: https://www.techopedia.com/definition/678/prototype
Priority: 4
Qualitative

-What is prototyping used for?

Source type: Secondary
Possible source: https://meee-services.com/what-are-prototypes-and-their-use/
and
https://en.wikipedia.org/wiki/Prototype
Priority: 3
Qualitative

Design Goal

sathiabali — 2019-01-23 03:18:09 UTC

To design a multi functional phone case on fusion 360, to facilitate traveling and make it more enjoyable for my clients. My primary research surveys demonstrated that people when traveling always have the struggle of having their power bank in their hands as well needing a place to put their AirPods in, the research showed that travelers would like a multifunctional phone case that can organize and hold their AirPods and incorporate a power bank. From my secondary research I’ve found the basics steps of manufacturing a phone case and all the requirements needed for one. While analyzing existing products I’ve realized many useful things that I could use for my project such as efficient and useful features and joints.

Target Market

sathiabali — 2019-01-23 03:18:18 UTC

This product is for all the travelers in the world with no distinction of gender, age or culture. The product provided is exclusively for travelers because it solves problems that occur mainly only when traveling such as lack of space efficiency and maneuverability of objects. The major things to consider in terms of aesthetics are the size since this object needs to be space efficient and also the materials will need to be resistant and durable because my primary research has proved that people have the necessity of a durable and small object which can still contain multiple objects.

WHAT I LEARNED ABOUT EXISTING PRODUCTS:

-The most common material used for phone covers is silicone
-A power bank usually has a USB plug to attach the charging wire as well as a micro USB plug to charge the power bank itself, the last thing that I’ve learnt about power banks is that they usually also have feature that shows the battery percentage of the power bank.
- I’ve also learnt that most phone covers or accessories attach to the phone from the back and most commonly the corners

Major constraints

sathiabali — 2019-01-23 03:18:24 UTC

The major constraints of this project will be the lack of some machinery required to use certain manufacturing process, another major constraint will be able to design a time plan that will allow me to finish my product on time. Also another constraint is the lack of silicone and leather in school which, according to my secondary research are the two most common materials used when manufacturing phone cases.

Success Criteria

sathiabali — 2019-01-23 03:35:15 UTC

The success of the project will be a space efficient and maneuverable phone case that solves the problem of losing the AirPods as well as providing a incorporated source of electricity for the phone. It will also have to appeal to the target audience and not just to the client. My research showed me that travelers clearly want a small and efficient phone case that can charge a phone.

Material

sathiabali — 2019-02-20 03:26:43 UTC

The product must be made out of ABS plastic because it has outstanding impact resistance, it is low cost plastic and it’s easy to machine since it is thermofrom
https://www.curbellplastics.com/Research-Solutions/Applications/Impact-Resistant

Drawing thumbnails (Initial ideas)

sathiabali — 2019-02-27 03:17:21 UTC

Paper model (Initial ideas)

sathiabali — 2019-02-27 03:19:37 UTC

sathiabali — 2019-03-01 14:21:57 UTC

Initial ideas: Fusion 360

sathiabali — 2019-03-01 15:14:08 UTC

Developed idea 1: Drawing

sathiabali — 2019-03-01 15:17:04 UTC

Developed idea 1: Play dough model

sathiabali — 2019-03-01 15:21:54 UTC

Developed idea 1: Fusion 360

sathiabali — 2019-03-01 15:23:31 UTC

Developed ideas 2: Drawing

sathiabali — 2019-03-01 15:30:09 UTC

Developed ideas 2: Fusion 360

sathiabali — 2019-03-01 15:31:30 UTC

Developed ideas 3: Drawing

sathiabali — 2019-03-01 15:32:22 UTC

Developed ideas 3: Fusion 360

sathiabali — 2019-03-01 15:33:28 UTC

Developed ideas 4: Drawing

sathiabali — 2019-03-01 15:34:38 UTC

Developed ideas 4: Fusion 360

sathiabali — 2019-03-01 15:35:59 UTC

Chosen design

sathiabali — 2019-03-06 03:01:57 UTC

This chosen design is a result of different features that I’ve selected from my thumbnails and developed drawings. Specifically, I’ve used to features from two different initial drawings that i’ve then developed in more and more developed drawings, the two features are power bank cases and airpods box phone cases which in this chosen design I’ve put together

Progression of AirPods box phone case design

sathiabali — 2019-03-06 03:14:18 UTC

Power bank phone case design

sathiabali — 2019-03-06 03:16:15 UTC

Why did I choose this design

sathiabali — 2019-03-06 03:35:41 UTC

This design best suits my needs because it follows my specifications and according to my research it would work well.

Final design

sathiabali — 2019-03-06 03:42:32 UTC

sathiabali — 2019-03-06 03:42:59 UTC

sathiabali — 2019-03-06 03:43:11 UTC

Additional informations about the design

sathiabali — 2019-03-06 03:54:37 UTC

The product is a 3D printed model, which means that is going to be a single solid piece and it wont involve any joints.
This design is a mix of my developed drawing 4 and 3, from N3 I’ve taken the idea of an AirPods box and from N4 I’ve reused the design of the phone cover as well as the idea of the power bank.

Measurements

sathiabali — 2019-03-13 03:30:48 UTC

sathiabali — 2019-03-27 02:58:40 UTC

Evaluation

sathiabali — 2019-03-27 03:00:21 UTC

The ergonomic of the handle suits the hand really well and it works quite well for the function it is used for but the shape of the handle isn’t wide enough because part of the blade sticks out.

Manufacture

sathiabali — 2019-03-27 03:05:01 UTC

1) Drawing of the design’s outline on paper
2) Cut out the external part to the outline of the knife of the drawing
3) Using the shape cut to then cut through the foam
4) Use a sanding tool to make the major sanding part
5) Use sand paper to smooth out the surface of the handle
6) Cut the insertion gap for the blade
Insert the blade and the chopsticks

Plan

sathiabali — 2019-04-09 03:53:32 UTC

In order to complete my design according to my B4 designs I will be creating a plan to organize tasks, by importance and urgency with the aim of finishing the product by April 24th. I will write down such plan in a table organized into five columns:
- Date
- Task
- Priority ( 1 to 5, 5 being the highest and 1 the lowest)
- Expected time consumption
- Explanation of the task

Materials & Equipment List

sathiabali — 2019-04-10 02:26:34 UTC

sathiabali — 2019-04-10 02:27:03 UTC

3D printing

sathiabali — 2019-05-03 04:19:38 UTC

In this skill I will just start the 3D printer after sending the stl file to the printer.

Sanding

sathiabali — 2019-05-03 04:33:56 UTC

This process should be occurring after printing, and it consists into using different types of sand paper based on the type of work that needs to be done. For example, I will use the normal sand paper to remove the bases of the printed model and the majority of the extra plastic prints and then I will use blue sanding paper to smoothen the surfaces and improve them aesthetically and physically.

This process occurs also after foam cutting and it also requires different types of sand paper for the different functions that I've explained above.

Washing

sathiabali — 2019-05-03 04:48:07 UTC

Once I’ve completed the processes of printing and sanding on my 3D model I will wash off the dust created from sanding.

Water proof test

sathiabali — 2019-05-17 04:18:31 UTC

In this test I am going to take a sample material of PLA plastic and poor water inside a concave cylindrical shape. The test will be successful if the level of water doesn’t change and no water goes through the material.

Results:

The water leaked through the plastic and the water level inside decreased so the test has failed

Material Durability test

sathiabali — 2019-05-17 04:44:32 UTC

In this test I'm going to investigate the pressure resistance of PLA plastic to know how durable the product will be. This is also important to know because while serving its function the product will most likely be found in situations that require durability for example when the phone falls of the customer's hand. I am going to investigate it by measuring how many rotations of the vice I can do before the material breaks, bends or cracks.

Results:

After 1 turn and a half the plastic gave signs of cracking. (cracking sounds) So i stopped and I checked the PLA piece and it was breaking.

Measuring

sathiabali — 2019-05-22 03:34:25 UTC

I've used this skill when I had to make the outlines of the phone model on paper to then cut thought on top of the foam.

Cutting foam

sathiabali — 2019-05-22 03:35:48 UTC

In this skill I used a carving knife and I made vertical cuts through the foam based on the measurements and the outlines done in the previous step.

Start modeling the initial shape into a the form of a phone case

sathiabali — 2019-05-22 03:42:58 UTC

In this part of the manufacture i starting modeling the rectangular block into the shape of a basic phone case.

Finishing the model

sathiabali — 2019-05-22 03:43:26 UTC

In this part of the manufacture I finished making the last part of the phone case which was the AirPods box and i also used the "fillet" function which is shown in D2 to improve the ergonomics and the look of the product.

Adding extra aesthetic features

sathiabali — 2019-05-22 03:43:35 UTC

In this part of the manufacture i just focused on improving the look of the product and i will do it by adding small details and carvings in the buttons.

Creating foam model

sathiabali — 2019-05-22 03:47:58 UTC

In this first part of themanufacture I made a foam model of my product as a prototype.

Creating initial shape on Fusion 360

sathiabali — 2019-05-22 03:48:00 UTC

In this part of the manufacture I just created a rectangular shape with the measurements obtained from existing phone cases mixed with my sketches and design ideas.

"Fillet" Fusion 360

sathiabali — 2019-05-22 03:49:57 UTC

I used this function to curve and round surfaces by adding fillets to one or more edges, faces or features.

"Extrude" Fusion 360

sathiabali — 2019-05-22 03:50:22 UTC

I used this skill on Fusion 360 to give volume to the objects, i used this function the most in the first step to the creating of the product by just pulling the 2D shape that i had drawn.

"Sketching lines" Fusion 360

sathiabali — 2019-05-22 03:51:03 UTC

I used this function of Fusion 360 to start off the basic shapes and draw outlines as well as for more specific things like creating outlines to then carve in the material with the extrude function.

Melting foam

sathiabali — 2019-05-23 00:56:15 UTC

I used this tool which heats up to quite high temperatures to carve the AirPods box holes in the foam model.

sathiabali — 2019-05-23 01:05:18 UTC

sathiabali — 2019-05-23 01:11:18 UTC

Printing model

sathiabali — 2019-05-23 01:12:39 UTC

In this part of the manufacture I've sent an STL file of the model to the printer and start printing it.

Sanding

sathiabali — 2019-05-23 01:13:46 UTC

Once It’s finished printing i removed all the extra plastic around the product and the lower bases.

Final 3D model

sathiabali — 2019-05-23 01:24:55 UTC

Final PLA model

sathiabali — 2019-05-23 01:25:01 UTC

Final foam model

sathiabali — 2019-05-23 01:25:18 UTC

Material

sathiabali — 2019-05-24 02:03:44 UTC

If I had to make this product again one thing that I would change is the material (PLA plastic) because it doesn’t protect the phone, AirPods and power bank from water as it is demonstrated in D1.

Ergonomics

sathiabali — 2019-05-24 02:03:54 UTC

The product although quite easy to handle is not very comfortable for the human hand to adapt to so I reckon it would be good to make the back follow a more ergonomic and natural.

Manufacture

sathiabali — 2019-05-24 02:04:07 UTC

The manufacture of this product is currently quite effective anyways it is a really slow and unreliable process because the 3D printers often fail and if they don’t it normally takes a minimum of 10 hrs to print one object of the size of my phone case. So if I had to do this again i would probably choose to make these with silicone using a mold.

Time management

sathiabali — 2019-05-24 02:04:37 UTC

I think the process of manufacture times are too long also because the manufacture and the treatments (sanding, washing) of the product take a minimum of 13 hrs which is way too long for a single product.
I also think that my time management wasn’t the greatest because I didn’t step by step follow my plan which i should have had

Comparing to specifications

sathiabali — 2019-05-24 02:05:07 UTC

Aesthetics:
This criteria is successful because the product’s features are all in allocated as planned, and it does include a curved surfaces in the back.
Understandability:
Although I haven’t made a product guide the product remains quite simple and easy to utilize as it’s shown in the graph below obtained from a survey. For this reason this test is a pass.
Long lasting: This criteria isn’t successful because the school now uses PLA plastic and not ABS plastic and even if I used ABS the model hasn’t printed yet and i only have a model made out of foam
Environmentally friendly: This criteria is also not successful because I haven’t made my model in ABS plastic but with foam which is bad for the environment because it’s made out of oil.
Manufacture: This criteria is also unsuccessful because I haven’t made my product with a mold but with a 3D printer and foam.
Costs: This criteria is successful because I didn’t exceed my budget for this project.
Customer: This criteria is successful because the product design is made for a iPhone 6s and it does make traveling easier.
Size: This criteria is successful because the product follows the size specifications and it didn’t exceed the boundaries
Safety: This criteria is successful because the phone case material is an insulator which is the requirement for this criteria
Function: This criteria is successful because it allows to do all the tasks required listen in B1.
Material: This criteria is unsuccessful because the product is made out of PLA and foam.

Airpods box test

sathiabali — 2019-05-24 02:08:51 UTC

In this test I am going to test if the AirPods box can actually hold real AirPods and the test will be successful if the AirPods fit int he box’s apposite holes. This test is going to be done on the foam prototype which isn’t as accurate as the final PLA model so it’s ok for the AirPods to not be static as long as they fit in.

Results:

As I expected the Airpods aren’t completely stable and firm anyways this test still is a pass because the AirPods DO fit in the box and the stability problems can be solved on the more accurate PLA model.

Function

sathiabali — 2019-05-24 02:16:06 UTC

The airpod case doesn’t have a top lid that can protect the top of the AirPods. There’s no risk of the AirPods falling off the box because the box will be magnified so the only issue is when the whole case falls or the AirPods get hit. So to improve this issue the best solution would be to make a lid like on the original AirPods box.

Size

sathiabali — 2019-05-24 02:19:33 UTC

I had to make slight changes to the size of few parts of the product due to durability and functions issues. The first one was that the AirPods box wasn’t wide and tall enough to fit box of the aipods. Also i had to make the phone case a bit thicker because it wasn’t durable and safe enough for the phone.

Material

sathiabali — 2019-05-24 02:22:53 UTC

I also had to make a foam model because the PLA model might not be printed on time.

Concavity of AirPods box

sathiabali — 2019-05-24 02:23:55 UTC

I’ve also changed a the holes for the AirPods slightly to better suit the shape of the airpods. This is a relevant change because it will help guarantee more stability to the AirPods.

sathiabali — 2019-05-24 02:25:47 UTC

The problem of unorganized traveling for my client is now solved because he can now carry his power bank his AirPods and his phone in once. This solves the problem of lack of musical entertainment and the issue of running out of batteries.

Also according to my criteria in D2 I’ve succeeded most of my criteria in B1, making my product successful

sathiabali — 2019-05-24 04:58:55 UTC

sathiabali — 2019-05-31 04:48:52 UTC