We started with a preliminary 2D sketch in AutoCAD to determine the feasibility of our mechanism (fig 1), then produced an animation in SolidWorks to test the mobility and range of motion(fig 2). A preliminary prototype(fig 3) was produced by using laser-cut linkages, 3D-printed shafts, shaft caps, spacers, and bearings with retainer rings. The process of building the preliminary prototype underscored the difference between the perfect CAD world and reality where laser settings, material types, and 3D print settings made a huge difference in tolerances which required a number of redesigns and testing to meet design requirements.
Preliminary Sketch Mobility check - SolidWorks animation Preliminary Prototype