Overview
This project is the result of three subjects. These subjects are part of one of the degree’s specialization: integrated design of consumer products.
In the first part, individually, we created a concept of the product with two concepts in mind: eco-friendly and streamlining.
In the second part, once decided the design, we were given electronics component and we had to create a prototype.
Finally, we did a mechanical analysis before printing it. Then we assembled and painted the prototype.
Stages
Group Project
Process
Conceptualization
Concept Sketches
Individual part
Concept chosen
With the concepts of eco-friendly and streamlining, we had to think of headphones that fit both ideas. To do so, the approach was to “streamline” the geometry and use materials and textures to aesthetically make them eco-friendly looking. In order to decide which concept we were going to develop, each studen made a render of the product in Autodesk 3DS Max. To choose it objectively we conducted some surveys and the winner was the last image
3D Model & Render
Virtual mechanical analysis
In this section, different tests have been performed. One simulation consisted of a 10-centimeter horizontal extension of the headphones, while the other one analyzed the response and performance of the headphones to a 2-meter drop.
These simulations were ran in Solidworks. I used this software as it includes a module of design (CAD) and a module of mechanichal testing (CAE). After running the first simulation, we noticed some weak points regarding the headband. To improve it, we increased the width of it and changed the location of some bolts. This way, we achived a better functional product without building it.
In the drop test, the material “Nylon 101” performed well. In terms of mechanichal endurance, the impact did not surparss the elastic limit of the material (60 MPa). To sum up, the design was mechanically strong. With these tests, we can ensure that the potential product will meet users expectations about durability.
As part of the integrated design of a product, we learnt some tools to virtually simulate the manufacturing process. In this case, we used Autodesk Fusion 360. We had to adapt the design a little bit to make it suitable for the milling process. We took into consideration some manufacturing aspects such as the diameter of the drill bit, the machine dimensions as well as the material starting billet.
Results
3D Print & Presentation
