Almost every product on the market has been through the hands of an industrial designer at some point in its development. From the phone in your pocket to the car in your driveway or the vacuum in your closet, the way things look and work is the result of a careful design process. Taking a look inside that process, like with this wireless phone charger concept, is fascinating and can yield really valuable design insights.
We’ve featured lots of [Eric Strebel]’s work before, mainly for the great fabrication tips and tricks he offers, like how to get a fine painted finish or the many uses of Bondo. But this time around, he walks us through a condensed version of his design process for a wireless phone charger and stand. His client had specific requirements, like being able to have the phone held up in landscape or portrait mode, so he started with pen and paper and sketched some ideas. A swiveling cylinder seemed to fit the bill, and after a quick mockup in PVC pipe, he started work on a full-size prototype in urethane foam. There are some great fabrication tips in the video below, mainly centered on dealing with not owning a lathe.
The thing for us with all of [Eric]’s videos, but especially this one, is seeing the design process laid out, from beginning to (almost) the end. He sure makes industrial design look like a cool gig, one that would appeal to the Jacks- and Jills-of-all-trades who hang out around here.
Continue reading “Wireless Charger Gives a Glimpse into Industrial Design Process”
STL files are everywhere. When there’s something to 3D print, it’s probably going to be an STL. Which, as long as the model is good just as it is, is no trouble at all. But sooner or later there will be a model that isn’t quite right in some way and suddenly project progress hits a snag.
When models interface with other physical things, those other components may not always be exactly as the designer expected. Being mindful about such potential inconsistencies during the design phase can help prevent problems, but it’s not always avoidable. The reason it’s a problem is because an STL file represents a solid model as a finished unit; it is not really intended to be rolled back into CAD programs for additional design changes.
STL files can be edited, but just like re-modeling a component from scratch, it can be a tricky process for those who don’t live and breathe this stuff. I’ll describe a few common issues related to STLs that can hold up getting that new project together, along with ways to deal with them. Thanks to 3D printing becoming much more commonplace, basic tools are within reach of even the least CAD-aware among us.
Continue reading “3D Printering: When an STL File is Not Quite Right”
Some folks just can’t leave well enough alone, and that often ends up being a good thing. Such is the case with this 3D-printed compressed air engine, which just keeps getting better.
The design has changed a lot since we first covered [Tom Stanton]’s attempts at reviving the powerplant from the glory days of the Air Hogs line of toys, which he subsequently built a plane around. The engine was simple, with a ball valve that admitted air into the cylinder when a spring mounted to the top of the piston popped it out of the way. That spring has always bothered [Tom], though, compelling him to go back to the drawing board. He wanted to replace the ball valve with one actuated by a cam and pushrod. This would increase the complexity of the engine quite a bit, but with the benefit of eliminating the fail point of the spring. With a few iterations in the design, he was able to relocate the ball valve, add a cam to the crankshaft, and use a pushrod to open the valve. The new design works much better than the previous version, sounding more like a lawnmower than a 3D-printed engine should. Check out the design process and some tests in the video below.
And speaking of lawnmowers that run on compressed air…
Continue reading “Cams and Pushrods Improve 3D-Printed Compressed Air Engine”
Going from idea to one-off widget is one thing; engineering the widget into a marketable product is quite another. So sometimes it’s instructive to take an in-depth look at a project that was designed from the get-go to be a consumer product, like this power indicating wall outlet cover plate. The fact that it’s a pretty cool project helps too.
Although [Vitaliy] has been working on this project for a while, he only recently tipped us off to it, and we’re glad he did because there’s a lot to learn here. His goal was to build a replacement cover for a standard North American power outlet that indicates how much power is being used by whatever is plugged into it. He set constraints that included having everything fit into the familiar outlet cover form factor, as well as to not require any modification to the existing outlet or rewiring, so that a consumer can just remove the old cover and put on the new one. Given the extremely limited space inside an outlet cover, these were significant challenges, but [Vitaliy] found a way. Current is sensed with two inductors positioned to sense magnetic flux within the outlet, amplified by a differential amp, and power use is calculated by an ATmega328 for display on 10 LEDs. Power for the electronics is tapped right from the outlet wiring terminals by spring clips, and everything fits neatly inside the cover.
It’s a great design, but not without issues. We look forward to seeing [Vitaliy] tackle those problems and bring this to market. For more on what it takes to turn a project into a product, check out our own [Lewin Day]’s story of bringing a guitar effects pedal to market.
Continue reading “Smart Outlet Cover Offers Lessons on Going from Project to Product”
[Tommy] is a one-man-shop making electronic musical things, but that’s not what this post is about. This post is about the outstanding prototyping post-mortem he wrote up about his attempt to turn his Four-Step Octaved Sequencer into a viable product. [Tommy] had originally made a hand-soldered one-off whose performance belied its simple innards, and decided to try to turn it into a product. Short version: he says that someday there will be some kind of sequencer product like it available from him, “[B]ut it won’t be this one. This one will go on my shelf as a reminder of how far I’ve come.”
The unit works, looks great, has a simple parts list, and the bill of materials is low in cost. So what’s the problem? What happened is that through prototyping, [Tommy] learned that his design will need many changes before it can be used to create a product, and he wrote up everything he learned during the process. Embedded below is a demo of the prototype that shows off how it works and what it can do, and it helps give context to the lessons [Tommy] shares.
Continue reading “Learn What Did and Didn’t Work In this Prototyping Post-Mortem”
If you buy a computer today, you’re probably going to end up with a laptop. Corporate drones have towers stuffed under their desks. The cool creative types have iMacs littering their open-plan offices. Look around on the online catalogs of any computer manufacturer, and you’ll see there are exactly three styles of computer: laptops, towers, and all-in-ones. A quick perusal of Newegg reveals an immense variety of towers; you can buy an ATX full tower, an ATX mid-tower, micro-ATX towers, and even Mini-ITX towers.
It wasn’t always this way. Nerds of a sufficient vintage will remember the desktop computer. This was, effectively, a tower tilted on its side. You could put your monitor on top, negating the need for a stack of textbooks bringing your desktop up to eye level. The ports, your CD drive, and even your fancy Zip drive were right there in front of you. Now, those days of desktop computers are long gone, and the desktop computer is relegated to history. What happened to the desktop computer, and why is a case specifically designed for a horizontal orientation so hard to find?
Continue reading “Whatever Happened To The Desktop Computer?”
Millions of people worldwide have just added new Apple gadgets to their lives thanks to the annual end of December consumerism event. Those who are also Hackaday readers are likely devising cool projects incorporating their new toys. This is a good time to remind everybody that Apple publishes information useful for such endeavors: the Accessory Design Guidelines for Apple Devices (PDF).
This comes to our attention because [Pablo] referenced it to modify an air vent magnet mount. The metal parts of a magnetic mount interferes with wireless charging. [Pablo] looked in Apple’s design guide and found exactly where he needed to cut the metal plate in order to avoid blocking the wireless charging coil of his iPhone 8 Plus. What could have been a tedious reverse-engineering project was greatly simplified by Reading The… Fine… Manual.
Apple has earned its reputation for hacker unfriendliness with nonstandard fasteners and liberal use of glue. And that’s even before we start talking about their digital barriers. But if your project doesn’t involve voiding the warranty, their design guide eliminates tedious dimension measuring so you can focus on the fun parts.
This guide is packed full of dimensioned drawings. A cursory review shows that they look pretty good and aren’t terrible at all. Button, connector, camera, and other external locations make this an indispensable tool for anyone planning to mill or print an interface for any of Apple’s hardware.
So let’s see those projects! Maybe a better M&M sorter. Perhaps a time-lapse machine. Or cure your car’s Tesla envy and put a well-integrated iPad into the dashboard.