GROUP REFLECTION

Overall, we're very happy with how our project turned out. For both of us, this class was our first experience with product fabrication, so we definitely learned a lot throughout the process. At the beginning of the project, we had a hard time need finding, so we instead focused on the mechanism we wanted to develop first. We decided pretty early on that we were going to fabricate a switch-like, compression spring based mechanism. However, it did not look as simple as it seemed, although we knew (based off of our coaches' feedback) that if we managed to execute all of the dimensions right, and found the right spring, that it would end up working great.

One of the big challenges we had to overcome was working with the spring shaft that would drive the lever. From what we had learned from our prototypes, we needed a spring shaft that would have a slit wide enough for a securing piece to go through (without becoming too thinly fragile), while thin enough for a compression spring to fit over it. During our first trip to ACE Hardware, the only spring we found that had a large enough dimension was way too rigid; the force of the shaft would not be enough to push down the spring and force the switch to the other side. We did decide, though, that 3D printing would be the best way to get the perfect dimensions for the spring shaft without compromising rigidity. Later, we happened to find another group who had a 1" diameter spring that was wide enough to fit our spring shaft, yet still loose enough to create the perfect preload that we needed.

In terms of fabrication processes, we had experience with laser cutting, but neither of us had ever used the 3D Printer, so that was a new and interesting experience to navigate, although we can both say that we are very happy to have acquired this useful skill. While fabricating physically was time-consuming but relatively intuitive to us due to the trial-and-error and hands-on nature of it, we struggled with the Solidworks aspect of this project. Neither one of us were particularly strong with the software, but, with the help of the Room 36 CAs, as well as many hours in Room 36/Huang Basement watching tutorials and trying new processes, we managed to get it done.

Our team dynamic was great. Our mutually open communication and open-mindedness towards new ideas proved to be successful in our creation of the Sleep Switch. Though scheduling was sometimes rough, given both of our extremely busy schedules, we always kept a positive spirit and managed to complete the project with satisfaction.

In the end, we were extremely pleased with our final product. We are glad to have really focused on the mechanical aspect of this project, as our bistable mechanism is very durable and always reliable. It might have been hard work, but the satisfaction of feeling the switch working so well every time is like no other! If we had more time, we would have loved to create an enclosure for the mechanism (as pictured in the 'Manufacturing' tab) for aesthetic purposes, as well as to protect the hardware and offer users the opportunity to set the product on a surface instead of always hanging it up. There are also a couple other minor aesthetic choices that we could improve upon, such as the rastering of the "Do not Disturb" and "Come on In" to be more visible from farther away, or potentially making the lever an arrow (or vinyl cutting an arrow to add to the handle) to make the message more clear. Despite all of that, we can definitely say that this project was a great experience, and that we are very satisfied with our execution of the Sleep Switch.

SPENCER

I really enjoyed the process of this project from designing to putting it together and learned many new skills. Making a bistable mechanism was far more difficult and totally different task than any of there assignments prior, and my partner and I knew this would be challenging but we were ready to learn.

Solidworks was a major part of this project as all our pieces demanded Solidworks, being either 3D printed or laser cut. Though at ties I faced many challenges when using Solidworks, challenges like getting the dimensions to fit with the other pieces or making the spring shaft small enough to fit the spinet around, I felt I became much better at using this software after this project. My skills developed because I needed to tinker a lot with the piece files, fixing mistakes, or making slight changes consistent throughout the project. I learned more general things like how shoulder screws work and all the different ways springs can be applied.

The best part of this project for me was definitely seeing our mechanism work. It was very satisfying seeing it work after putting a ton of thought and time into it. One part of the project I feel like I would change or do if I had the time was put more work into the user interface of the switch. Originally we had designed out a more complex design of an enclosure around our switch but we had to simplify it due to time constraints. But I am still very happy with our project and it was a great experience overall.

CHLOE

Overall, I really enjoyed this project of bringing The Sleep Switch to life! ME102 was my first real experience with fabrication and working in the PRL. As a result, a lot of elements proved to be a challenge, but now, being on the other side of it, I am very happy to have picked up these useful skills, and look forward to applying my learning in future projects as a Product Design major.

One thing I quickly noticed was how this project was a conglomeration of all of the homework assignments we had done so far in the class. As a result, the project did not seem completely out-of-reach, yet I understood that since the homework assignments were my first time being exposed to all of the subjects, that this project would still be a challenge, but ultimately solidify the skills that we learned.

In terms of ideation, it was a fine balance between what we wanted to create and what was feasible given time and knowledge constraints. There were definitely times where my partner and I had underestimated the time that something would take, and ended up spending much more time—or simply running out of time—because something went wrong on the Solidworks assembly or measurements did not line up the way we expected, for example. We learned from those times, though, and became much better at budgeting time as we moved further along the project.

In terms of fabrication, I had become very comfortable with the laser cutter before the project had even started, so my main concerns were Solidworks and 3D printing. Although 3D printing turned out to be much more intuitive than expected, Solidworks still continues to be a big challenge for me. My partner and I spent a ton of time asking CAs and watching tutorials to try to put our assembly together, and I think that that was our biggest point of frustration. But, throughout the process, it also became our biggest point of growth. Time was another element that got in the way during our project, as both my partner and I have really demanding schedules. It became harder towards the end of the project when my partner had to to leave campus to play in the NCAA Championships, but we tried to pre-plan as much as we could and made it work, still keeping communication open and moving along in the project while he was gone.

Overall, I am very happy with how our project turned out. We reiterated our mechanism many times, so seeing it work so sturdily and reliably is such a nice reward. The product is simple, practical, and reliable, and can find many uses, so I am quite proud of it. I also like the aesthetic touches we added to the piece. Moving forward, there are definitely some things we could fine tune. While I believe this piece to be pretty complete for door hanging purposes, we did plan on creating an enclosure for the piece that could be explored. I think also moving beyond the bistability and adding more states in which the mechanism could be—and therefore "settings" that the user can apply— would also be very interesting. At the beginning of the project, we had discussions about the Geneva mechanism, which is not bistable, but could be something interesting to explore for future iterations of the project. All in all, I'm very happy with this experience and how our final product turned out!