This project was part of the Materials and Processes for Product Design Module.
Besides the design process it taught 3D CAD modelling using OnShape, creating and using moulds, and the casting process. The overall goal was to demonstrate understanding of the relation between material properties, manufacturing processes and the design of a product.
Other processes and principles and their impact and implications for the design of a product were also taught as part of the module.
The Brief was to create a decorative drawer/door knob all the way from conceptualisation to prototyping the final design.
It is a requirement for the final prototype to be cast out of resin using a 3D printed mould. The design must be contained in a maximum cubic space of 40 mm x 40 mm x 50 mm and it must be configured exclusively by extruding and/or revolving 2D profiles. Additionally, it must feature the University logo either raised or in recess. Overall the design must come out of the mould in one part.
After some initial research the design process was started off by creating some sketches to explore a variety of shapes as well as possibilities on how a knob can be attached to the door.
Once a design was chosen this was further explored through additional sketches and then the final type of airplane was folded in order to create a model to help explore the amounts of layers the finished design will have and their relation to each other.
This model also helped to create some final notes for the CAD that gave further details on dimensions and considerations that will help with the CAD and later placement of the knob on the door.
In the next step the CAD model was created in OnShape before shelling the part to create a mould suitable for 3D printing and casting.
Finally, the 3D printed mould was used to cast the part using a resin mix.
After de-moulding the part it was slightly sanded to minimise imperfections and get a smoother surface.
