Role

Individual project

Responsibilities

Design, prototype, and manufacture the final product

Skills

3D Printing (FDM), CAD, Machining (Mill), Sand Casting, Welding, Woodworking

I designed and created from scratch a Taiwanese sky lantern inspired night light. I learned and executed machine shop skills such as machining, woodworking, welding, and sandcasting.

Hero Shot

Sand Casting

  • I used Fusion 360 to design my pattern and iterated to compromise between draft angle, functionality, and aesthetics in CAD.
  • The pattern was 3D printed in PLA in two parts with integrated fixturing holes on the base.
  • The patternboard was created from scratch according to the size of the cope and drag.
3D printed pattern and patternboard Pattern in sand before the pour Cast aluminum base

Machining (Mill)

  • Steel tubes (0.375” OD, 0.065” wall thickness) were fishmouthed at 8.6º and 28.6º to form the frame of the lamp
  • The sand cast base was machined to form the shallow recess for the lamp to sit in

Welding

  • 20 steel tubes were welded together using TiG welding with mild steel as the filler material.