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This is a KS4 Engineering project that my year 10's do (14 year olds). It gives the students choice and the opportunity to work creatively. The outcom...
Nature is by far the best engineer, it creates the strongest structures, it makes the most beautiful designs, and its secrets have been the inspiratio...
Give the students pre cut card to the size of the materials provided Blue card = 155 x 110mm Black card = 155 x 110mm White card = 130 x 125mm ...
Create a final design page, its important that the students add design detail of how the design is going to be made. This makes your life much easier ...
We use SolidWorks but if you don't have any 3D software there are free CAD packages like Autodesk's 123D or google sketchup..... Both of these can pro...
Using precut aluminium 110 x 155 x 1.2mm Using the dimensions developed from the 3D virtual modelling stage measure and mark out the aluminiu...
Shape the aluminium using rollers for curves and folding bars for right angles Use 150grit abrasive paper to remove any marks from rolling
Using precut acrylic 110 x 155 x 3mm the students need to mark out their design, the sheet can be cut into a shape or used complete. Leave th...
Using a Ø5mm drill bit and a pillar drill create the two holes as per your marking out Ensure goggles are worn, hair tied back and sleeves ro...
Use a sanding board with 150grit paper on it to remove saw marks from all four edges I also used wet&dry paper to polish the edge
Set an oven to 170oC / If you do not have an oven you can use a heat gun / paint stripper We use aluminium formers, other options are MDF or ...
Provide the Ø38mm ally tubes pre cut 20mm bigger than the ally sheet Face both ends Use a half round file to remove the burrs inside the ...
Use a digital calliper to accurately measure the diameter of the tube (i know its standard Ø38mm tube but the kids do not) Place the tube in ...
Measuring from the bottom of the tube, then drill, using a V-Block, centre punch and drill Bolt Holes Ø4.2mm The bottom hole will be 20mm The top hol...
Using an M5 tap thread the four bolt holes
Using a lathe set to low speed, and 150 grit abrasive paper......sand the tube. The second picture shows the difference between sanded and not sanded....
Parallel turn the top of the lamp on a metal lathe. Turn the cutting tool at a 45degree angle to cut the O-ring channel
Knurl the grip....use low speed...(approx 100RPM) Part off the work
Use Ø8mm aluminium rod Centre drill Drill Ø5mm approx 30mm deep Sand Part off at 13mm Repeat 3 more times
Use epoxy resin to stick on the Ø5x1mm neodymium magnets.
Using 4 super bright LED's, 360 ohm resistor, PP3 9v battery and the magnetic contact create the circuit as per the diagram.
Use insulation tape to protect any exposed wire, you must do a good job of this as the LED legs are particularly vulnerable to shorting on the ally tu...
Carefully add the circuit to the ally tube.....careful is the word if you force the circuit you are likely to snap wires I use a plumbing pip...
Use M5x20mm bolts to assemble the aluminium and acrylic sides
Here are some examples of students practical and 3D CAD work, they made a version that is used to light up something on a desk e.g. Homework or keyboa...
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