3D Designed Box: Round 1

Before you ask, even I don’t know what the picture is. It’s weird and cool. I like it.

For a long time I had been keen on doing Physics. Pure Physics. Understanding how different things around me work on a fundamental level, and for a long time the only way I knew how to do just that was pure equations and math, on pen and paper. Of course, I was aware that computers are essential in everything around us but I never knew how to properly utilise them.

Simultaneously, I always got the feeling that I never fully appreciated and exploited the power of computers, whether it was a mac or windows. Now when I fire up Fusion 360 and start designing a box for a breadboard ([below] a component you can connect other components to using wires) or designing the base plate for a drone (yeah, no jokes!) I feel like I’m a superhero. Cringey, I know.

I’m taking a class right now which introduces students to different types of industry-standard skills related to electrical components and applications we can use throughout our career in the sciences. It’s a really cool class. Even though it’s only the first time the instructors are teaching this particular course I think they’re doing a phenomenal job. To be completely unbiased, I don’t have other data points to compare to, but that’s just the annoying scientist in me talking. The class is cool 🙂

Coming back to the design for a box to fit a breadboard, here is my current one:

All of the above is done by yours truly. The lid has an interesting structure (credit to my friend). I knew I wanted a hinge to support the lid, however there were many ways I could go about that. I could create a literal hinge out of plastic 3d printed, such as the following:

However, I recognised two problems with this when I went in to design it.

One, the 3D printer prints bodies separately, and in this type of hinge the two bodies are attached by the hinge. Sure, you could even print it. However, you obviously want the bottom half and top half separate. I guess you could ass supports in the middle, but all in all seems too tedious and sensitive. 3D printers like the one I was using aren’t that precise. They get the work done, but not in the best way.

Second; it’s very likely when I actually tried to bend the PLA (Polylactic acid – the material used for 3D printing) it would snap off. Too weak. Especially for a relatively large and heavier lid than the hinge itself. Maybe other types of plastic would be better.

My friend brought up the idea of door hinges, and how I could potentially push a 3D printed rod through the hinge. The rod would be fixed in the hinge (but allowed to move, perhaps with some sort of cap) somehow, and it would work. To me, an absolute beginner in 3D printing and having literally zero experience with the material, it again seemed too tedious and perfect. What if the rod had too much friction with the hinge, it being plastic after all? Seemed like a long-shot try.

Perhaps it would work with a different material. Upon some tinkering with ideas, I decided on using a strong metal wire, bent over from inside the lid somehow, and as it poked out of the side of the box, I could bend the wire and push the wire through holes on the lid, as seen in the diagram. Of course, the wire is a separate piece, not 3D printable (I didn’t even know that was a word).

The rest was rather simple.

Just like all villain arcs, my 3D prints failed. Miserably. Credits to another friend:

Seems like the 3D printer had a beer or two before showing up to work. I’m genuinely baffled how this happened because when I was there for the first 20 minutes of the printing it worked flawlessly. Just have to try till it works, I guess. Still sucks.

Even though I was quite disappointed, this whole process of designing a body for the breadboard has been quite thrilling. As of now, definitely more interesting than the physics I’ve been learning. Now don’t get me wrong, I still enjoy it. The thrill of finding meaning within all those equations and extracting an answer is still sky-high. Perhaps it’s the enjoyment of trying something new which is playing with me, but my emotions say I’m appreciating the more hands-on stuff more. Let’s see where that takes me.

The drone design is for another post. I promise, I’m not lazy. I’m just really sleepy. On a separate note, this my first post in a long time because I never previously prioritised my own passion and fun in writing these posts. I’ll try to do more of that. If on that journey you find my articles interesting and discover interesting things along with me, I’d love that. If not, your loss :))