CS 285: SOLID MODELING, Fall 2011

Another Team-based Design Challenge -- the teams:


The Goal: Design a Modular Part for Injection Molding

In this next assignment we focus on the design of a simple snap-together tile
that, in the end, will be suitable for injection molding, -- so that it can be made in large quantities.
The various phases of this assignment will guide you through the whole process
and will expose you to the many different concerns at different stages of the design process.

The goal is to make some mostly flat, modular, snap-together tile
that can be used to explore and prototype some interesting curved 2-manifolds as shown below:

        

     


As a starting point you may consider some tiling systems that are sold as children's toys:

 
Polydron tiles                                                                            Jovotoys

 
Extensions of the Polymorf system                                                                         Lego-Hinges




However, these systems normally do not allow to make surfaces of varying curvature ...  :-(

Your first assignment is to come up with creative ideas how to get around this problem!

Again, we will do this in several phases; starting with open-ended conceptual ideas,
and then gradually narrowing it down to a possible feasible product;
-- ideally, a small set of tiles that can be produced by injection molding with simple two-part molds.

A#9: Phase 1):  Generate some model/visualization of one or two tile types, focussing on the way
that these tiles interconnect and may be used to create surface patches of various curvatures.

Send me your first conceptual idea descriptions by Monday, Nov 14,  2pm.

A#9: Phase 2):  Develop one workable idea for a tiling system to prototype "curved" surfaces.

Teams:  Send me your refined ideas by Wednesday, Nov 16, 2pm.

A#9: Phase 3):  Create a detailed geometry description of the mold of your chosen tile,
or an STL file for a prototype FDM part, if the tile is clearly moldable with a simple two-part mold.
In this case orient the STL file so that the two halves of the mold would be above and below the part;
the test then is, that there is no intermediary support material anywhere in the part (only at the bottom).

Teams:  Send me your solutions by Monday, Nov 21, 2pm.



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