Phone Case and Stand (SLA 3D Printing), Hand Glider (HP MJF 3D Printing), Candy Dispenser (Laser Cutting and 3D Printing)

This phone case was printed using Formlab's Form 3 SLA printer. The case part was created using their Flexible 80A resin, while the stand part was created out of their Tough 1500 resin.

The main advantage of a 3D printed phone case is that it allows for rapid customization, whether it be for sizing for different phones, or for personal detailing. This project required many prototypes; I had to design the tolerancing on the case part to create a snug fit on the phone, because the flexible resin allowed for stretching. The hinge stand required many prototypes because it utilized a print-in-place hinge to allow for rotation. This type of assembly is much more common in FFF 3D printing, and thus required many different designs to find a working solution. Lastly, FEA analysis was conducted on the hinge axle to ensure that it would withstand repeated use.

This glider was printed on an HP Multi Jet Fusion, using their HP High Reusability PA 12. It has a mass of 15 g.

The goal of this project was to create a fully 3D printed hand glider; however, the catch is that this constructed using a 3D printing service and therefore could only be printed once, and could not be iterated upon. Therefore I designed-in features to allow for iterations to key glider characteristics such as center of mass, through the placement of a coin in a press-fit slot. The wings and rudder were printed as separates parts in order to reduce the supports required, and also utilize a press-fit to join to the fuselage.

Design Choices to Improve Flight: This glider features a high wing placement and high vertical stabilizers to allow for more stability at slower speeds. It uses mass-efficient design by minimizing the fuselage cross section and using hollow wings.

This candy dispenser is designed to hold and dispense small spherical "candies" one at at time, and to reset the mechanism after every actuation. It was constructed out of laser-cut acrylic, stainless steel hardware, and 3D Printed PLA.

The middle photo displays a prototype created out of wood, pink foam, and foam core, used to test the effectiveness of the rotating disk dispenser. The image on the right shows the orthographic drawings and exploded view to assist with final parts assembly.