My initial idea for my personal design project is a container for lotions in pump bottles. I have sensitive, dry skin, especially in the winter or when allergens are more present. My skin requires specific lotions in order to keep my skin hydrated, thus requiring a higher need to avoid waste. I seem to always have "not quite empty" bottles of lotion scattered around. I have to hydrate my skin at least once every day and it drives me a bit crazy when I'm running low and have to force lotion out of the bottle(s). Trying to extract the rest of the lotion from the bottle before disposing of the container is very tedious. I've gone as far as using a box cutter to cut the top portion off the top, so I could use the bottom of the bottle acting as a tub, but without a lid.

My design idea would allow the user to access the lotion that remains in the bottom of the bottle when the pump is no longer able to pull the lotion up the tube and extrude it via the pump nozzle. It would allow the lotion from the nearly empty bottle to be funneled down into the main cylindrical segment (by twisting off the top piece that covers the funnel segment), then into the base compartment that twists off and allows the user easier access to lotion with ease. I will continue to work on the functionality of the design itself, as I have had a few other ideas on how to design it to make it more versatile.

Supplies

Sources - Products and Photos

Elegoo PLA Filament - Galaxy Purple:

https://www.amazon.com/dp/B0CHS65ZSH?ref=ppx_yo2ov_dt_b_product_details&th=1

Elegoo PLA Filament - Mint Green:

https://www.amazon.com/dp/B0CHS65ZSH?ref=ppx_yo2ov_dt_b_product_details&th=1

Box Cutter

Trader Joe's Saddle Potato Crisps can and yogurt cup for rough prototype - testing options for sizing and slot shape:

https://www.traderjoes.com/home/products/pdp/sea-salted-saddle-potato-crisps-062910

https://www.traderjoes.com/home/products/pdp/meyer-lemon-cream-yogurt-078212

'Keeffe's Skin Repair Body Lotion, 12 Oz:

https://www.amazon.com/gp/product/B01M72IZSC/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

Gold Bond Medicated Eczema Relief Skin Protectant Lotion, 14 oz:

https://www.amazon.com/Gold-Bond-Eczema-Relief-Ounce/dp/B00OW9OTMK/ref=asc_df_B00OW9OTMK/?tag=hyprod-20&linkCode=df0&hvadid=309802573355&hvpos=&hvnetw=g&hvrand=13931527174317005149&hvpone=&hvptwo=&hvqmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9053026&hvtargid=pla-573050150532&psc=1&mcid=cb03c65f158d3b2f801719917ea110b1&gclid=Cj0KCQjwlZixBhCoARIsAIC745DU_Hxyo69i_bEz4n9Q7PFK1DpDuzotFPaCgmT97VyDCE6ZdvNCA3MaAhadEALw_wcB

Step 1: Sketches and Decision Making Process

I tinkered with various ideas for the material that would be appropriate for the design, being that it would mainly be used for toiletry items like lotions, shampoo, conditioners, or even different types of sauces and condiments. I created a couple of prototypes with items I had around my house for measuring and scaling purposes, primarily for the interior funnel. First is my initial sketch, where the interior forms are represented using dashed lines. I used the chip can lids to cut or draw shapes onto, so I could test the versatility of different lotion bottle lids. I used a chip can lid to cut out a slot, so I could insert a silicon funnel (because it is flexible and collapsible) into the slot making a flat surface that was easier to measure.

Step 2: Start Drawings of Lid Slot in CAD Software

Next, I began creating electronic design prototypes for the lid using the student version of Autodesk Fusion 360 (link below). They are represented here in chronological order from left to right. This step was the most difficult because I am rusty in CAD design and have barely used Fusion, and I couldn't test the threads or angle or the funnel until I printed the parts.

https://www.autodesk.com/products/fusion-360/overview?mktvar002=5022374|SEM|1618310827|64140214467|kwd-45199965798&utm_source=GGL&utm_medium=SEM&utm_campaign=GGL_D-M_Fusion-360_AMER_US_eComm_SEM_BR_NEW_EX_0000_5022374_F360&utm_id=5022374&utm_term=kwd-45199965798&mkwid=sVNT0EayL|pcrid|647555398762|pkw|autodesk%20fusion%20360|pmt|e|pdv|c|slid||pgrid|64140214467|ptaid|kwd-45199965798|pid|&utm_medium=cpc&utm_source=google&utm_campaign=GGL_DM_Fusion-360_AMER_US_eComm_SEM_BR_NEW_EX_ADSK_3529781_&utm_term=autodesk%20fusion%20360&utm_content=sVNT0EayL|pcrid|647555398762|pkw|autodesk%20fusion%20360|pmt|e|pdv|c|slid||pgrid|64140214467|ptaid|kwd-45199965798|&gad_source=1&gclid=Cj0KCQjwlZixBhCoARIsAIC745C86uR2n14BTHcmOE2HxOZtot-8mK9409Xnn0gy2ALA8pv_xhPSswkaAtFvEALw_wcB&ef_id=ZhVJOwAEmn-2hgBi:20240422170134:s&term=1-YEAR&tab=subscription&plc=FSN

Step 3: Create 3D Drawings for Body & Base

I drew and printed multiple variations of all three parts - the lid, base, and main compartment. This is where I was able to use my measurements and 2D sketches to create and print 3D versions allowing me to have tangible objects to test threads, overhangs, and the shape slope of funneled areas. These small prototypes were very useful, because I was able to observe where issues appeared, mainly overhangs and threading issues.

These photos show my initial full assembly drawing. Compared to my final attempt, these parts had sharper overhangs and the threads were much closer together and placed inside the body.

Step 4: Print First Mini Prototype

After printing these three pieces and assessing them, I found that the threads didn't not fit well at all, and the overhangs for the bottom of the funnel were very obvious.

Step 5: Adjust Drawing Overhangs & Threads, Then Reprint

I adjusted my design to use threads that were further apart and placed them on the exterior of the body (interior of lids and base) to increase the likelihood of printed threads that fit well together. I also adjusted the funnel overhangs, which can be seen in the section views. I placed both drawings in this section for comparison purposes.

Step 6: Finalize Print Design

This is my final drawing for the time being, but I will continue to adjust and print until the problem areas no longer exist. I also would like to create space in the base of the lid to add sand for weight to create a stronger base.