|Isometric view of the finished product in Solidworks.|
|The first real change, oval shaped to rectangle.|
|Frontal view of the first 3-D model.|
|Inside view of the first 3-D model.|
|Frontal view after changing from the large bulky rectangular box.|
|After adding the latch and hinges. (closed)|
|Frontal view of the holder after the belt clip was attached.|
As you can see in the pictures above, the latch was simple. I attempted using other locking mechanisms but this one worked the best. One other thing that is very noticeable in the image above, is the durability of the materials. At this stage of design, the cardboard was starting to separate and tear. However, there was benefits to this, it showed me what areas of the holder were the weakest, and that might break even on a model of stronger material. This is when I decided to cut off the handle. The handle I'm referring to is the thin piece at the very top of the design with copper wire bent around it.
|After cutting off the handle.|
|Before rounding the hinges.|
|After rounding the hinges.|
I've been asked a lot of questions while designing this so I thought it would be appropriate to compile a general Q & A section.
Q: Was the physical model hard to make?
|Left side view of the handle bending.|
Q: What made you want to design an allen key holder?
|Original hinge concept design, drawn by Mr. Grosinger.|
Q: How different was your first model from the final design?
A: My first model was immensely different from my last. The first model was an oval shaped holder, with no way to secure the allen keys in place. It was a flat piece of cardboard and the allen keys basically just hung in place, and would easily fall out. Slowly, I started adding on bits and pieces until I got to the model you see now.
Q: So, What made you change your original design?
Q: Okay, so the cardboard model revealed some flaws. What changes did you make to correct this?
A: The first change I realized I had to make was, going from a 2-D to 3-D model, a flat piece of material wasn't going to cut it. Secondly, I needed something to hold the allen keys in place, without securing them they would fall out no matter what else I changed. Later on I made improvements, but these were really the only things that I changed.
Q: How did you secure the allen keys?
A: My first attempt at securing the allen keys was by adding clips on the back of the holder. I believed the short end of the allen keys would clip in and stay firmly in place, but the clips were extremely difficult to make out of cardboard. With the clips not working mechanically how I pictured them, I decided it was time to try a new design. This is when I started to design the door and latch, which ended up working exactly how I wanted it to. It left enough space so that it didn't put too much pressure and break the holder when the allen keys moved, but enough strength to hold them in place.
Q: What was you biggest challenge?
|A failed attempt at 3-D printing the door.|
Q: What other problems did you encounter while working with the 3-D printer?
|Printing without a raft.|
|A third attempt at printing the door piece.|
|Better example of the piece bending.|
Q: Once you make a 3-D plastic printed prototype, how do you plan to test it in a real world scenario?
A: I plan to take my 3-D printed model with me to work over the summer. I will be working in the electrical field again, over this two month period I will see how my design holds up.
To be continued...