Prototyping
Whistle Project
During my first year at university, I participated in a lab session focused on creating a working whistle. Through precise machining and attention to detail, I successfully produced a functional whistle with accurate dimensions and a clear, resonant sound.
Steps to Create the Whistle
Facing and Drilling the Billet:
I began with a 100mm billet, securely placed it at the center of the lathe, and faced off the end to ensure a flat surface.
Using a center drill bit, I piloted the end, followed by drilling a 42mm deep hole with a 4.5mm drill bit. I then re-drilled the same length using a 6.5mm drill bit to widen the hole.
Turning the Outer Diameter:
I turned down 65mm of the billet to a diameter of Ø11.12mm.
To create the lip feature, I machined a 3.0mm-long section, reducing the diameter by 0.56mm.
Cutting and Radiusing:
After removing the billet from the lathe, I cut off the excess material using a hacksaw.
I then used the lathe again to radius the opposite end for a smooth, rounded finish.
Milling the Wind Hole:
From the radiused end, I removed 8mm in length and 5mm in depth using a milling machine.
To form the wind hole, I milled at an angle, creating an 11mm depth cut, positioned approximately 12mm from the drilled end.
Fitting the Internal Component (Billet B):
I prepared a second billet (Billet B) with a diameter of Ø6.52mm and a length of 25mm.
The top of Billet B was carefully filed down to reduce its height to approximately 4mm.
I then fit Billet B into the wind hole of the main billet (Billet A) by carefully hammering it into place. Once correctly positioned, I cut off any excess material using a hacksaw and filed the surface smooth.
Drilling and Finishing:
I marked the center of the flat surface and drilled a Ø3mm hole using a pillar drill.
Finally, I filed all surfaces to ensure a smooth finish and optimal functionality.
Arduino UNO Project
During my second year at university, I learnt how to program and operate an Arduino UNO to control servo motors and utilise ultrasonic sensors for automation. As shown in the picture, I successfully programmed the Arduino UNO to send appropriate data to a servo motor, enabling me to control its speed and change the direction of rotation between clockwise and anti-clockwise.
From the video, I further implemented an ultrasonic sensor to measure the distance between the sensor and an object, which in this case was my hand. I developed a program that stops the motor when the sensor detects an object at a distance less than 10 cm.
In addition, I created another program to reverse the motor's rotation when the ultrasonic sensor detects an object at a specific distance or less. However, I did not record a video demonstrating this particular functionality.
Chair Prototype and Computer-Aided Design
This image shows a physical prototype of a chair made from card. The design features regular sitting areas connected to seats that include a working desk positioned in front, extending from the top. This demonstrates my ability to create functional prototypes even when access to high-quality materials is limited.
Building upon the physical prototype, I developed a Computer-Aided Design (CAD) model of the chair using Fusion 360’s sheet metal tool. This transition from a card prototype to a digital design highlights my proficiency in CAD software and my capability to refine and enhance initial ideas. By recreating past prototypes digitally, I can explore further improvements and present ideas in a more polished and adaptable form.
Mars Rover Prototype
The image on the left shows an initial prototype of a Mars Rover, constructed using cardboard. This early model allowed me to explore the design, structure, and wheel functionality, while utilising simple and accessible materials to bring the concept to life.
Building on this prototype, I created a refined version of the Mars Rover, shown in the image on the right. This version features laser-cut plastic for a more durable and precise structure, paired with toy wheels for improved functionality. The transition from a basic cardboard model to a polished plastic design demonstrates my ability to develop and enhance prototypes using advanced techniques and materials.
This project highlights my creativity, technical skills, and commitment to iterative design, taking an idea from concept to a functional and visually improved model.