Festive Shield

For this project, we designed and then manufactured a shield using our combined knowledge throughout the year on CAD design, CNC manufacturing, and tool use. The main goal of this project was to create a functional shield, but also to apply the skills learned from Advanced Mechatronics, Manufacturing, Engineering Mechanics, Coding, and Digital Electronics. This shield was meant to be durable enough for a fight but also decorative for a festive sign.

Supplies

30"x24" Wood Sheet

Christmas Lights (Battery Pack)

Black Spraypaint

Beltgrinder/Sandpaper

CAD

CNC

Jigsaw

Belt

Step 1: Design

We wanted to create a visually appealing shield for the holidays, but that was also functional in real life. It had to be structurally strong and able to cover the average person's torso. The shield's shape underwent various changes during the design phase, from sharper corners to curved sides. While searching for shield designs, one stuck with us the most, which was the Shield from Zelda, we replicated it as much as possible in OnShape (CAD Software). The Shield from Zelda has nice, sharp curves and a large face to defend against attacks.

Step 2: CAD Design

The Shield in Onshape was dimensioned to be able to take most of the space of the wood sheet but able to leave spaces on the edge for the CNC Machine. The shield is 18 inches across and 25 inches tall. The wood for the shield is approximately 3/4" thick, allowing for sturdiness and for it to be lightweight. The sharp corners were made by using a conic tool, each being 0.5". The design was approved by our team and then exported in a DXF File ready for the CNC machine.

Step 3: CNC Machnining

We used a CNC machine to cut out the outline of the shield; it cut about 1/2" down. The machine ran over the outline 4 times to allow for a precise outline; the machine tool was checked, and wood chips were vacuumed out during each cycle. After the CNC machine was done, the outline was then fully cut out by using a jigsaw.

Step 4: Sanding and Painting

Once cut with the jigsaw, the edges were very rough, so it was then put on the belt sander to allow for smooth edges for the lights to be placed on. The front of the shield was painted black to allow a company to put its decoration on the shield.

Step 5: Handle and Lighting

A belt was cut in half, then screwed on the back of the shield to allow for your hand to slide through the first, then hold on the second for a sturdy grip. A battery-powered Christmas light pack was then hot-glued on the edges of the shield to provide a festive lighting, and the battery pack was hidden behind the shield.

Step 6: Final Assembly

After all the components were added, we tested the lights to make sure they functioned correctly, and the belt was secured. We originally used tape for the lights, but that failed, so we opted to use hot glue for more sturdiness. The Shield also took some hits, but our team and other students saw if it was protective enough, which it passed.