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Description: During my senior year at Northwestern, I designed, modeled, and 3D-printed a phone case for my final project in Rapid Prototyping, a mechanical engineering design concentration course requirement.
Course: DSGN 348-0: Rapid Prototyping
My Role: My primary role during this project was as the sole designer, modeler, and printer of a 3D-printed phone case. Working alone, I completed the design process for an original product via rapid prototyping. I utilized the additive manufacturing methods of Fused Deposition Modeling and Polyjet Printing to 3D-print my prototypes, gaining skills for product design and 3D printer operation.
Cell Phone CAD (SolidWorks)
Cell Phone CAD (SolidWorks)
To begin the design process, I produced sketches showcasing the projected design features of my phone case
I translated this design into SolidWorks and modeled the first iteration of my cell phone case
I modified the CAD of my phone case over the course of the project, iterating based on fit tests and user feedback
The cell phone case CAD was 3D-printed at each iteration, culminating in a final phone case
Fit + User Testing
Fit + User Testing
In order to achieve the best cell phone design, feedback had to be collected regarding the phone case's fit and individual user preferences
I tested the fit of each phone case iteration after 3D printing, improving its fit by extending the lip of the case around the phone's outer edge
I conducted user testing by surveying 5 respondents in Ford, collecting feedback by allowing them to hold it and answering predetermined questions
Fit and user feedback data helped identify the strengths and weaknesses of my design, informing design improvements to the case's feel and aesthetics
3D-Printing
3D-Printing
Over the course of the project, I used a variety of 3D-printers and materials to manufacture the three iterations of my cell phone case
I printed my first model on the Prusa MK3 using blue NinjaFlex TPU to create a flexible fit-testing model
I printed my second model on the FormLabs Form 2 using Elastic 50A to create a rigid and flexible phone case
I printed my third and final model on the Connex using Shore 95A to create a firm yet flexible phone case that can hold cards
I learned the basics of using different models of 3D-printers and produced prototypes rapidly for a product I designed myself
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