CS 285: SOLID MODELING, Fall 2011

Assignment #7: A Team-based Design Challenge

The Teams:

STUDENT, NAME E-MAIL
TEAM Z
JIN,YUN (Jessi)   babyface@berkeley.edu 
KWON,YOUNGWOOK PAUL  young@berkeley.edu 
OKAMOTO, YASUHIDE yokamoto@berkeley.edu
WANG,BRANDON M    brandonwang@berkeley.edu 


TEAM Y
KUMAR,PARDEEP     pardeep@berkeley.edu 
LAM,HUYSON YAT-CHI  huysonlam@berkeley.edu 
LEE,ANDREW       a.lee@berkeley.edu 
LODHA,SURYAVEER SINGH  slodha@berkeley.edu 


TEAM X
LU,CHENG (Eric)  ericlv88@berkeley.edu 
MITCHELL,TOBY JAKE  tobymitchell@berkeley.edu 
WILLIAMS,JEREMY MICHAEL jeremywilliams@berkeley.edu 


TEAM W
DOERING,FREDERICK  frederick.doering@berkeley.edu 
GREWAL, KAWALDEEP  kawaldeep@gmail.com
KO,JONATHAN EDWARD  jonathan.ko@berkeley.edu 
YE,HANZHONG (Ayden) aydenye@berkeley.edu 



The Challenge:

Design a two- or tree-piece geometrical puzzle in which the shapes separate from one another by a helical/helicoidal motion.
Ideally, all pieces should have the same shape (mirroring is OK).

This is much tougher than the bell design, because we now have to deal with multiple parts that must fit together.
Accuracy, tolerances, and clearances become important issues!

What to do:

Meet at the regular class time, Wednesday October 5, 2011, at 4:10 pm in the classroom 606 Soda.
Find your group; then sit together in a corner of 606 or find a space in an alcove elsewhere in Soda Hall.
Briefly introduce yourself to one another and assess your strengths and expertises that you each bring to this task.

Brain-storm to find possible conceptual solutions for the stated challenge.
Start by trying to obtain clarity on the separating surfaces, along which the parts touch and slide to separate.
Then define an overall outer shape that distracts from, and hides, the motion by which the parts separate,
and which makes the puzzle look intriguing and difficult to solve -- particularly, putting it back together!

Capture your conceptual design in a form in which the idea can be clearly conveyed to a party not present at your discussions.
This will probably be some sketches and explanatory text, possibly already an approximate SLIDE file;
perhaps some kind of model made from clay or carved from styrofoam ...

E-mail me your designs by Monday, 10/10/2011, 2pm,
and bring any models or other physical artifacts to class.

If you need clarification, send me e-mail.

Have fun! -- and train your spatial perception skills!

Narrowed-down and Clarified Specifications -- and Some Hints and Insights:


Pairs of identical parts should share enough of a helicoid surface, so that they are held firmly in an unambguous final position.
When the parts start to separate, they should slide along that helicoid surface.

For creating a design following the above specifications:
Think of two pieces separating with a tightly constrained prismatic sliding motion;
then apply a helical twist along the sliding axis to the whole geometry.

When you cut this assembly in a plane perpendicular to the helical axis, you should see a pattern with C2 (or C3) rotational symmetry.

Phase 2 of the Design Process: 

All Teams:  Revise your design to get closer to the above specification
and create a viable B-rep of a puzzle part that can be fabricated with layered manufacturing (FDM).

Due: Wed. Oct. 12, 2011,  2pm.


Phase 3:
After receiving feedback on October 12, finalize your design and create a valid STL file of your part
-- properly scaled and oriented for manufacturing.  Make it fit into a 2-inch cube.

Test-slice your design with QuickSlice to make sure that everything is OK
-- without the need to edit any bad yellow SSL curves!

E-mail me a pointer to the final debugged STL file by Monday, Oct. 17, 2011, 2 pm.

I plan to have these parts built on the newer, more precise Stratasys machine with a disolvable support material.

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