PROBLEM
Design and make a bespoke jewellery box
SOLUTION
PROJECT TIMELINE
Setting and following inter-project deadlines is vital to a successful long term project as it breaks down the project into more manageable pieces.
This timeline was created in my first week of the project with help from my teacher to ensure I was spending the right amount of time on each section of the project and to help organise my time.
RESEARCH ACTIVITIES
After establishing main topics to research I was able to identify specific primary and secondary research activities for each of those areas.
A mind map was used using different colours to provide a clear layout of my thought process.
I then was able to undertake my research activities including an in-depth analysis of 4 different existing products, a questionnaire with 38 responses, anthropometric and sustainable materials research. An evaluation of each method was also included to show the reliability of the research.
INITIAL DESIGNS & EVALUATION
Starting with 10 different designs using nature as inspiration, I used user feedback, checks against my specification and focus groups to screen and score my ideas to help choose my final design.
I also produced working models and CAD models to see how the user would interact with the product and to provide a 3D visual of the design.
My final design has four main components; a larger bottom space for holding general jewellery, a layer on top holding several smaller sections perfect for rings and earrings, a protective layer on top and the bolt fixed in the bottom layer to aid in opening and closing the box easily.
MANUFACTURING SPECIFICATION
These three images surmise the needed information for manufacture. It includes the materials sizes and costing as well as the manufacturing methods.
A production sequence plan was also produced for the manufacture of the plywood body of the box. This helped me structure my class time effectively.
Google Sketchup was used to create the CAD models and basic engineering drawings and 2D designs was used to create the pattern for the plywood and acrylic to be cut on the laser cutter.
MANUFACTURE
I thoroughly enjoyed my manufacturing experience as I was able to learn how to use the lathe for the manufacture of my bolt. For the main section of the bolt I started with a ⌀20 mm and turned down to ⌀14 mm, taking off 0.2 mm each time to protect the cutting bit.
The threaded section was turned down to ⌀6 mm before using a 6 mm die and tap set, using the lathe and trefolex (cutting compound) I was able to cut the thread.
The other main components of this product were all laser cut out of plywood, clear acrylic and blue foam. To create a smooth surface to be spray-painted I sanded down the exterior of the product using an iron sander and then filled the holes with filler and hardener and then repeated the process until fully smooth.
6 mm tap and trefolx was used to carve the thread
The final manufactured bolt
Testing the bolt fits well in the captive nut
Turning down and facing off my bolt in the lathe
