Manufacturing and Assembly - AC

Manufacturing was relatively simple after design as translating from CAD to 3D print is almost instant. This is especially true as I knew I was going to be 3D printing, so the links remained simple and generally 2.5D, with no overhangs. The main issue in the manufacturing was actually the printing time for the base. The initial base was a large rectangle with a lot of wasted space, and would have had a printing time of 8.25 hours. In order to reduce this time, I first reduced the thickness of the base from 1/4 to 1/8", as the links I printed initially were thick enough to be halved if need be. I then reduced the profile of the base to include only the locations where links would need support. This included the path of link 1 and link 3, as link 2 is the slotted piece and is held above the base by the two other links and the middle pin. The resulting profile is below.

After printing the base and the slider block, I found that link3 could fall into the slot for the slider block, which could bind up the mechanism. To fix this issue, I change the profile of link 3 to add a wider section in the middle, allowing it to bridge the gap. At the same time, I also reprinted the other links to extend the pins 1/4" higher, to allow for easier manipulation of the mechanism and reduce the chance of the pins disengaging.

Link 3 before adjustment to prevent binding

Link 3 after adjustment to prevent binding