Window Shutters Press-Fit Construction Kit
What will it do?
My aim is to integrate as many digital fabrication techniques as possible to create an electronically actuated product that is easy to produce, fabricate, assemble and use.Since I’m interested in furniture design and fabrication, I decided to create automated window shutters that are programmable to fold and unfold depending on light conditions.
Key Specs:
- The operable shutters are to be designed to allow of user customization, through the alternation of designs placed in slots within the shutters- Controlled via Fabduino
- Hinges/ Joints are 3D printed
- Incorporate engraving techniques to improve the overall aesthetic appearance of the product.
- Dimensions : 60 X 50 X 6 cm
- Weight: 11 kgs
Whose done it beforehand?
Carpenters, interior designers, furniture designers, furniture stores. Design inspirations:
What materials and components will be required? Check BOM
- 60 x 80 x 0.4 cm Plywood
- 125 x 250 x 1.3 cm Plywood
- 120 x 160 x 0.5 cm Plywood
- 50 x 20 x 1.5 cm Acrylic
- 2 Swivel Casters
- PLA (Joints and Hinges)
- Fab ISP programmer
- Fabduino
- 2 Servo motors 13 kg/ cm
- Photoresistor
Where will they come from?
- In Fab inventory
- Sparkfun: Photoresistor
- Servei Estacio : Plywood + Swivel Casters
- HobbyKing: Servo Motors
- Digi- Key: Fabduino Components
What parts will be made?
The product is composed of:
- Main frame: Laser cut/ engraved plywood
- Shutters: laser cut acrylic. Laser cut/ engraved plywood
- Fabduino
- All joints and hinges
What processes will be used?
- Arduino IDE: To program the micro-controller
- Eagle: Electronics design
- Rhino+ Grasshopper: 3D Mechanical/ Product design and modeling
- Lasercutting
- 3D printing
How much will it cost?
|
Fabduino |
|||||
|
No. |
Material/Component |
Quantity |
Unit |
Unit Price |
Price (EUR) |
|
1 |
ATMEGA 168A |
1 |
Item |
1.26 |
1.26 |
|
2 |
Red LED SMD |
1 |
Item |
0.15 |
0.15 |
|
3 |
499O Resistor |
1 |
Item |
0.06 |
0.06 |
|
4 |
10k Resistor |
1 |
Item |
0.06 |
0.06 |
|
5 |
0.1 uf
Capacitor |
2 |
Item |
0.13 |
0.26 |
|
6 |
1 uf
Capacitor |
1 |
Item |
0.13 |
0.13 |
|
7 |
10 uf
Capacitor |
1 |
Item |
0.13 |
0.13 |
|
8 |
Switch Button |
1 |
Item |
0.48 |
0.48 |
|
9 |
Female Header |
1 |
Bag |
2.7 |
0.8 |
|
10 |
FTDI Header |
1 |
Item |
0.7 |
0.7 |
|
11 |
Photoresistor |
1 |
Item |
1.1 |
1.1 |
|
12 |
Copper Prototype Board |
1 |
Board |
3.54 |
3.54 |
|
13 |
Copper Sticker |
1 |
Piece |
2.02 |
2.02 |
|
|
Sub- Total |
10.69 |
|||
|
|
|||||
|
Main Frame |
|||||
|
14 |
Plywood 12mm |
125 x 250 cm |
Board |
- |
24.5 |
|
|
Sub- Total |
24.5 |
|||
|
|
|||||
|
Shutters |
|||||
|
15 |
Plywood 4mm |
60 x 80 cm |
Board |
8.3 |
8.3 |
|
16 |
Plywood 5mm |
120 x 160 cm |
Board |
11.89 |
23.78 |
|
17 |
Acrylic 15mm |
35 x 25 cm |
Board |
1.39 |
10.45 |
|
|
Sub-Total |
42.53 |
|||
|
|
|||||
|
Other |
|||||
|
18 |
BMS-630 MG Super Strong Servo
Motor |
2 |
Item |
22.07 |
45.4 |
|
19 |
PLA Filament |
38 |
cm3 |
0.3 |
11.4 |
|
|
Sub-Total |
56.8 |
|||
|
|
|||||
|
|
TOTAL
(EUR) |
123.84 |
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What tasks need to be completed?
Checklist (Marked Y is complete):
|
2D- 3D Design |
||
|
1 |
Produce sketches and 3D
model to better visualize my idea |
Y |
|
2 |
Define the mechanism of
the folding system |
Y |
|
4 |
Test and modify the
press-fit slots |
Y |
|
Electronics |
||
|
5 |
Design the Schematic on
eagle |
Y |
|
6 |
Design the board on
eagle |
Y |
|
7 |
Fabricate the board |
Y |
|
8 |
Solder the components |
Y |
|
9 |
Test and fix the board |
Y |
|
Laser-cutting/ Engraving |
||
|
10 |
Cut & engrave the
layers of the main board |
Y |
|
11 |
Cut & engrave the
layers of the shutters |
Y |
|
12 |
Cut the joints of the
shutter frames |
Y |
|
13 |
Cut the Designs |
Y |
|
14 |
Cut acrylic joints |
Y |
|
3D Printing |
||
|
15 |
3D Print joints for one
side of the shutters to test the mechanism of the joints (minimize friction) |
|
|
16 |
3D Print the hinges for
one side of the shutters to test the mechanism of hinges (Minimize friction) |
|
|
17 |
Modify (if needed) and
3D print the remaining parts |
|
|
Programming and testing the motors |
||
|
18 |
Write the script |
|
|
19 |
Test the script |
|
|
Assembly |
||
|
18 |
Assemble the fabricated
parts |
|
|
19 |
Modify and fix any
unforeseen errors |
|
|
20 |
Install the servo motors |
|
|
21 |
Check & fix alignment/
centers issues |
|
|
|
|
|
What questions need to be answered?
- Will I be facing problems concerning friction?
- Will I need an external power source to power the two servos? If so, do I need to add a voltage regulator?
What is the schedule?
The aim is to practice supply- side management by allocating time per task/requirement.
- Design:
- 3D conceptual Model: 1 Day
- Mechanical Design: 1 Day
- Preliminary design 1 day
- Fabrication and Testing:
- Main Frame fabrication and programming 1 day
- Shutters fabrication and testing with acrylic joints 2 days
- 3D Printing 3 days
- Assembly:
- Assemble parts and test for errors 2 days
- Find solutions and modify errors 1 day
- Final Presentation preparation 1 day
how will it be evaluated?
My ultimate goal is to apply diffrent fabrication methods and to be able to understand the various machines and equipment interms of potential, functionality and limitations. I will channel a large amount of my efforts on making all the parts rather than buying them. Futhermore, I hope to develop my programming and electronics production skills as mine were almost inexistent before I attended the Fab Academy.
The prototype requires integrating various processes (electronics design, embeded programming, 3D design and modeling, 3D printing, laser-cutting and mechanical design), my objective for the final presentation is to have a working protoype, designed and fabricated with ease of assembly in mind, strategiacally employing press-fit construction techniques.
