1 - Simple, Whimsical, Fun

2 - Sketching 

3 - Stages of Prototypes

I started with a low fidelity prototype made from pink foam, acrylic tube, dowels, paper, and hot glue to explore how this mechanism might work. Next, I explored using materials closer to my final product to explore how bearing would work, how much structural support I would need, and how I would attach the pictures. Then, I laser cut main structural pieces out of acrylic and assembled a high fidelity prototype with metal connecting components to get a better sense of shape, size, and function. Each step taught me a lot and guided the final product.

4 -Building and Trouble Shooting

I used Solidworks, a mill, a rotary table, a lathe, drill press, and other machine shop tools to mock up and manually machine the components of Cascade. 4 of my pieces for cascade needed to be milled on all 4 side and on the top face. I had to use clamps in one position, mill, then move clamps in another position, mill again, and repeated that until I had milled all side of my piece. For milling the top face, I used machining tape to hold my piece down, and had to mill in the face in very small increments.

Troubleshooting Post-Processing

I added an inset ridge to my design for aesthetic purposes and I had to design a tool for me to be able to sand this part of this piece. I laser cut a sanding fixture that I attached sand paper to so that I could finish and polish this piece.

5- Final Product

6 - Learnings

1. Mentally prepare by visualizing processes to optimize time in machine shop

2. Ask questions early and often to gain perspective. Filter and synthesize as needed.

3. Prototype early and often.

4. Wrap and take care of pieces, immediately. Clean up after yourself.