In late 2017 Birkenhead High School Academy, GDST, contacted our Liverpool lab to discuss how we might be able to work together providing some manufacturing experience to its A-level design students, through some kind of design and manufacture challenge.
Design one - Cactus
The Cactus design was the first to be translated in to a 3D model from which we could print, requiring a little design interpretation around the stand and the “arms” that held the phone, it made sense to extend the base of the flower pot to act as a ledge to hold the phone, and use the upright of the cactus “arm” as guides to stop the phone falling off the side. I then designed a small hinge to allow the Cactus to be folded up when not in use.
Design Two - Elephoney
The elephant is a great interpretation of the design challenge, using the trunk to hold the phone upright and in position. The original drawing was traced out into the design software, and then extruded into a 3D shape with a little refinement to ensure the trunk prescribes a clean and smooth arc. To give a more premium finish to the Elephant, laser cut perspex sides will be attached with small 3D printed caps, which will be bonded in to place.
Design three - Kolin
Colin was the name loosely thrown around for this particular take on the challenge, an exclusively 3D printed design like the Cactus, but in the name of stylisation, the C was substituted for a K. It was agreed with the designer that the arms and head should be a different colour to the body, and so they were printed separately as part of a second assembly that bonds to the back of the main body using conventional Cyanoacrylate super glue, 3D printed plastics tend to respond well to this assembly approach as the natural grain of the material due to the printing process encourages a strong bond between parts.
Design four - Mouth
The mouth is unique among the four designs, in that it is majority laser cut where the others are majority 3D printed. With more time the teeth could be fully modelled and 3D printed, then bonded on, but for the sake of this exercise, and given time constraints (particularly with the students needing to consider a production approach) the teeth have been flattened and simplified as part of the laser cut perspex. The construction is to be layered, with a 3D printed spacer to create clearance for the phone, and the stand design from the cactus repurposed in a new colour to support the holder on a desk.