Monday, June 4, 2018

3D Printed Game Soccer Goal Post

Challenge: Student was interested in producing a game of table soccer.  As part of the game he wanted to have a clearly defined goal post for the game.  He had tried cardboard versions of the goal posts but wanted something that would be more robust and permanent.
Background: Student was looking at ways to produce goal posts for the game mentioned.  There were various designs that the student looked at creating, including attempting to replicate existing versions of this print.  The student had attempted to design this from scratch but was not satisified with their results, relative to other versions that were available.   It is also worth mentioning that the student concerned is nine years old and this was his first attempt at 3D Printing - he has seen other projects that students have worked on but is developing his confidence with 3D Printing.
Level of Difficulty: Low - this is intended as an ongoing project which the student will produce a series of prints associated with the game.  The print is straightforward, the engagement with the student is as important as the process.   Creating the goal-posts as the student has done will drive the game itself foward as the rest of the details will follow the size of the goal.
Timeframe: Five hours - there were versions of the print that included netting etc but the decision was made to focus on the poles and to keep the design basic.
Size: The width of the deisgn was 110mm.   The back of the design was 120mm long.  The height was 100mm.   The various poles that make up the goal posts were 10mm thick.   We are intending to test the strength of the goal posts relative for the game and would be looking at redesigning these if prove to be not strong enough. 
What we would do differently: We would look at road testing this design to ensure that it would work.  The print was produced as a single file - there was considerable discussion about the printing of the individual goal posts and then super-gluing all the pieces together post printing.   We decided not to do this as the student wanted to be successful with their print run.
Next Steps for Students: As mentioned this is looking as developing a game as part of wider project.

Saturday, June 2, 2018

Summary of Classroom Projects

This slideshow is a summary of projects that are School/Classroom related. They include a brief description and a link to the original post on this site.

3D Printed Shower Caddy Replacement

Challenge: Student wanted to manufacture a replacement piece of a shower caddy/shower storage shelf for his shower at home.  Original piece was broken through use and he wanted to create a replacement.
Background: Student is a senior student (twelve years old) who has worked through our school system.  He has used the 3D Printers and our Laser Cutters for a considerable length of time.  This student has worked on a number of major projects of increasingly difficulty and shown flair and design with his creations.  This replacement part was designed and 3D Printed so it could be replicated exactly to replace the broken part.  It needed to work as part of a larger piece and needed to fit in perfectly with an existing piece.   The 3D Printer was utilized in this example because the part would be exposed to water on a daily basis.    This is the students first attempt at completing the part and the measurements etc were completed independently and designed in Tinkercad. 
Level of Difficulty: High - for a school student context this is about as complicated project that we have seen in the last four years from our students.   Every aspect of this print needs to be correct for it to work in unison with an existing part.   Each of the slots fits into an existing part. 
Timeframe: Nine hours.  The base of the shelf in this design is extremely thin, with a width of 2mm.The intention is for a potential reprint once the print itself once the print is proven to be successful, with that in mind a considerable increase in the print time would be expected by the nature of the base being the most significant feature of the print itself.
Size:   The dimensions of this print is slightly deceptive.   The base measure 140mm across by 120mm the wings at the back of the design are 40mm hight.  As noted in previous description the width of the design is only 2mm thick in places, something to be considered if the project is to be redesigned. 
What we would do differently: This project was created and designed exclusivley without input from the teacher.   The project was to solve an issue at home, where the student had independently identified that a 3D Printer would be the best tool to solve this problem and replace a part that needed to be.   Other than the width of the thickness of the shelf, it is, in our opinion an example of an extremely high calibre.
Next Step for students: With the print complete the student is currently checking its suitability, the only issue of note is ensuring that the slots are accurately aligned with the shower piece and that the width of the shelf is adjusted to take the weight on shower items. 

3D Printed Oversized Key Ring - Part Two.

Details - This is the second print in this series.  This is a second version of the same key, as explained in detail the School has dual PE Sheds, a student and teacher. 

Having Laser Cut wooden versions of these key rings, which are delibrately oversized to ensure that students (or staff) are not able to easily put them into their pockets.  The laser cut versions worked well however their high use meant that the wood they were cut into became stained and looked untidy.  It also saw the need to be redrilling the key hole as the wood started to wear.   The solution devised by our students was to 3D Print two matching keys, which were then 3D Printed.  This design was based on the original print detailed here previously with the only changes to the print being the lettering, which was modified to reflect the key, the other change was to switch PLA from bright red to grey for easy identification.  Print time and all other details identical.

Wednesday, May 30, 2018

3D Printed Oversized Key Ring

Challenge: Student wanted to create an oversized key ring as a gift, which then became an attempt to create something to solve an ongoing issue with a high use key in the school.
Background: Student wanted to design an oversized key-ring that would allow a family friend to not loose a significant key.  This then led our students to identify another issue that was ongoing here at our school.  We have an extremely high use student key, which we have previoulsy produced a key holder wall mount for.  The key ring has been used extensively (it is used everyday by students).   As a encouragement to return the key to the place that it needs to go, it had been laser cut into MDF piece of wood and labelled 'Student PE Shed'.   What we found was that while this worked perfectly well the high use of the key meant that the MDF became stained and also broke during repeated use.  The solution was to look to our 3D Printer to ensure that we produced a more robust version of this
key ring.  We used the 'tractor' key-ring as the inspiration and produced a 'Students PE Shed Key' as a response, to solve that issue at the school.  The student who produced the 'Tractor' key ring was
Level of Difficulty: Medium.   This is a straightforward print dominated by the basic Tinkercard interface features.   The students in both examples have followed a format with the design, the width and the shape are the same, the interchangeable features are the hole, which is slightly modified, the font for the heading identifying the keys and the image.
Timeframe: Four hours.  Both key rings came in within ten minutes of each other.   There are a series of designs along a similar theme planned particularly for the extremely high use keys that belong to the school which students or teachers are using on an extremely regular basis.  There is going to be a change in PLA filament to ensure that the key rings are colour coded.   These are already significantly oversized at present to mean that the people who are using them are unable to put them in thier pocket.
Size: While there are two distinct prints in this set, they have the same essential dimensions, which is delibrate as they are working from the same base.   The base measures 100mm across, 90mm high and having a width of 8mm.      The lettering in both designs was 2mm above the base, and the football was sunk very slightly into the design (1mm).  At the end of the day these keys are being used by mutliple students everyday to access common areas and therefore they need to be robust.
What we would do differently: By creating this project we believe that we have solved a problem or an issue that has arisen in the school.  This is taking the practical use of the 3D Printer to improve something, and hence we would only make minor adjustments to the letter of the PE Shed Key. 
Next Steps for Students: Looking for other projects to complete that will solve a problem using the 3D Printer.

Monday, May 28, 2018

3D Prtinted Badge on stand

Above: Design shown from above
Challenge: For student to produce a unit and personalized badge of themselves, their first 3D Print which they had worked on individually.
Background: Student has been wanting for a considerable time to complete his first significant print.   He had seen projects and designs from other members of the classroom and wanted to experiment with the use of feet as a stand.  He was using standard Tinkercad settings and creation options.   He wanted to involve the 'chicken feet' option for the base of the design.  He also was interested in using the new 'Dinosaur' design that has recently been made available to create.   The design of the name itself was basic and the holes that the student had potentially available were made redundant by the fact that the student decided to mount it on the chicken feet.  These feet proved to be slightly problematic.  The feet themselves are thin when printed and removal of rafting around the base of them can lead to them breaking.  In this case a block need to be attached to the top of the leg, super glued to the base and then held in place until it had set. 
Level of Difficulty: Medium.  The issue was with the feet of the design, and the dinosaurs claws that were on the far side of the design.
Time frame: Four hours for the base of the design (this also included the claws that can be seen in the photograph).   The feet were printed in forty five minutes and the blocks that were used to mount them to the base took forty five minutes.
Size: The main base is 120mm by 60mm.  It had a width of 20mm.   The feet are shown to scale.
What we would do differently: The project was more of an attempt for a student to try his hand at 3D Printing for the first time that produce a completely coherent print.   The student was very positive about the experience and enjoyed the final product.   He thought that the chicken legs were unique.  The base with his name raised into it was basic and could have had the students name with a capital letter.  There was no need for the hole in the base of the design, this was created to hang the design from the wall. 
Next steps for the student: This student has taken his first steps with 3D Printing and has made considerable steps and plans already with more complex projects.

Wednesday, May 23, 2018

3D Printed Student Stationary Organiser

Above: Completed project in overview
Challenge: Student wanted to produce a stationary organiser for her sister to use in the classroom to organise her classroom equipment.  Background: This student had produced a number of prints and designs in the classroom both this year and last year.  In this task she was looking for a gift to give to her sister that would have a purpose and a use.    There were a number of examples of this type of design many of which were featured on this blog both last year and this year.   The student who created this project is ten years old.
Level of Difficulty: Medium - this project had a number of aspects to it, all of which that needed to work to ensure that it was successful.  The design as created and shown in photographs had been somewhat inspired by other class projects.   The unicorn shown above the students name and to the left was the same design as featured in the 'recycled' project from two posts ago.  The cylinder designs shown in the photograph and the box are all from the basic Tinkercad interface.   The idea between the 'l' shape design shown in the back left hand corner was to allow a ruler to be slide into place.
Timeframe: Sixteen hours was the total for the project, while this may seem to be quite considerable some of the other projects in this series have approached or been over the twenty hour mark, the key difference is the width or the thickness of the cylinders.  In previous versions these have been as thick as 20mm.   These cylinders are no more than 5mm thick.
Size: Square base of the design is 120mm by 120mm.   The width of the base plate was 5mm.   The cylinders height varied from 50mm to 100mm to 120mm.  The height of the unicorn was 40mm.
What we would do differently: Minimal - the project intentions, given the brief and what the student wanted to achieve were completed.   There was a slight issue with some 'banding' with a slight lip created which can be seen in the photograph above right.  This has appeared from time to time with our prints when a layer is produced that is off slightly.  We believe this is caused by the feeding of the PLA filament into the back of the machine, which occassionally can be tight due to the roll of filament not unravelling correctly.  There were some basic and small amounts of filament that were missing from the name of the student.
Next Steps for Student: This project has been completed and the student needs to move onto other projects, and there is nothing else required to complete this.  Having said this there could have been component parts printed or completed that could have been assembled post printing.