Padlock

Materials:
3d Printer,

3d Filament,

Pens with springs in them,

Glue

Step 1: Making the Pins

For the top pins you want to create a new part in SolidWorks and set the measurements to MMGS. After that you want to create a sketch on the top plane and sketch a circle with a diameter of 4.5mm. Extrude that circle out 7mm then fillet the bottom of the cylinder by 1mm. Save the part as TopPins and create a new part for the first bottom pin.

For the first bottom pin you want to have your new part open and create a sketch on the top plane. Then create a circle with a diameter of 4.5mm, extrude it out 7mm, and fillet the bottom by 1.5mm. Save this part as BottomPin_1 and keep the part open, so you can create the second bottom pin. For the second bottom you want to take your extrusion of the first bottom pin and add 1.5mm to the extrusion to make it 8.5mm tall. Save this part as BottomPin_2 and keep it open for the third and final pin. For the third bottom pin you want to do the same thing you did to the second pin of add 1.5mm onto the extrusion except you want to add it to the height of the second extrusion to make it 10mm tall. Save this part as BottomPin_3 and create a new part for the spring and pins holder.

Step 2: Making the Pins and Springs Holder

For the springs and pins holder you want to have your new part open and sketch a 7mm by 25mm rectangle on the top plane. Then you want to extrude the sketch by 25.75mm. After you extrude the sketch, select the bottom face of the part and click reference geometry and click plane. Then raise the plane to be on top of the rectangular prism at 25.75mm above the bottom.

Next you want to go to the right side of the part and click on extrude then select the right face of the prism. Then you want to sketch a 3 point arc from the top left corner to the top right corner and give the arc a radius of 10mm. After that you want to sketch a line from the top left corner of the prism to the top right corner of the prism to get a closed shape. Exit the sketch and extrude the part out 25mm over the other part.

After you extrude the new sketch you want to select the side that you originally selected for the second sketch and create a new sketch on that face. There you want to sketch a circle in the center of the arc from sketch two and make a circle with a diameter of 18mm. Then exit the sketch and click on extruded cut. After that click on the third sketch and cut out the circle. Finally you want to select the plane you made earlier and create a sketch on that plane. The first thing you want to do in this new sketch is sketch a rectangle in the same size (7mm by 25mm) and place as the first sketch. From there you sketch a three circle with and diameter of 5.00mm with one in the center one to the left and right. Then smart dimension the distance between the circle to be 7mm for each one. After you want to delete the rectangle you sketched in this sketch and exit the sketch. Finally you want to extrude a cut from the circle with two directions. One direction is into the rectangular prism 24mm, and the other is up into the circle 2mm. Now Select the left side of the holder and create a new sketch like in the picture. After that you want to sketch a centerline through on the face and then sketch a center rectangle from the center of the face. Smart dimension the rectangle to be 23mm by 2mm like in the picture. Now you want to Extrude a cut using the sketch you just made and cut into the holder by 27mm. Then save the piece as Holder and open a new part.

Step 3: Making the Key

Now that you have your new part open the first thing you want to do is start a sketch and sketch a rectangle 40mm by 2.25mm. Then from the center of that rectangle you want to sketch another rectangle that is 25mm by 2.25mm. After that delete the smart dimension for the longer rectangle.

The next thing you want to do is sketch a diagonal line up from the top right corner of the longer rectangle. After you do that you want to take a centerline and draw it straight down from the top of the line that you just drew and connect it to the top of the rectangle then start your smart dimensioning for this centerline. The first thing for this smart dimensioning you want to do is make the centerline 8mm tall. The next thing you want to do is smart dimension the point of the bottom of the centerline to the top right corner of the smaller rectangle making it 1.5mm away from from the corner on the INSIDE of the smaller rectangle. Afterwards you want to sketch a line diagonally downwards from the top of the other diagonal line that you made. Then do the same thing you did for the first diagonal line a draw a centerline straight down connecting it to the top of the rectangles. Then smart dimension the centerline to be 3.5mm tall and 3mm away from the top right corner of the smaller rectangle. Next you want to sketch a horizontal line that is 5mm long from the bottom of the last diagonal line that you made and make it go towards the left side of the rectangles. Next you want to sketch a line straight down from the left end of the horizontal line you just drew to the top of the rectangles. Now sketch a diagonal line up from the end of the horizontal line and sketch a centerline straight down to the top of the diagonal line to the top of the rectangles. Smart dimension the the centerline to be 8mm long and 1mm from the bottom of the previous centerline that was made. Then from the top of that diagonal line you just made sketch another line down diagonally and at the bottom of that line sketch a centerline straight down to the top of the rectangles. Then smart dimension the centerline to be 5mm long and 1mm from the previous centerline. After this you want to draw a horizontal line from the bottom towards the left side of the rectangle and make it 5mm long. Then create a centerline straight down to the top of the rectangles and from the top of the centerline, create a diagonal line going up and to the left. From the top of the diagonal line sketch a centerline down to the top of the rectangles and smart dimension it to be 8mm tall and 1mm from the previous centerline you made. Now sketch a diagonal line down and at the end of the line sketch a centerline straight down to the top of the rectangles. Smart dimension the centerline to be 6.5mm tall and 1mm from the previous centerline. Afterwards you want to sketch a horizontal line from the bottom to the left of the diagonal line you just made and smart dimension it to be 5mm long. From the end of the horizontal line, sketch a centerline straight down to the top of the rectangles. After that sketch a diagonal line up and to the left of the horizontal line and at the end sketch a centerline straight down and smart dimension it to be 8mm long and 1.5mm away from the previous centerline. Now you want to sketch a horizontal line from the top of the diagonal line towards the left of the rectangles. Smart dimension it to be 1.5mm long. Now sketch a vertical line up from the end of the horizontal line and smart dimension it to be 3mm long. Then sketch a horizontal line to the left of the of the top of the vertical line and smart dimension it to be 7.49mm long. From the end of the horizontal line sketch a line straight up and smart dimension it to be 6mm long. Now sketch a horizontal line from the top of the vertical line towards the left and smart dimension it to be 15mm long. The next thing you want to do is sketch a 3mm line straight down from the bottom left corner of the Smaller rectangle. Then sketch a horizontal line to the left from the bottom of the line you just made and smart dimension it to be 7.49mm long. After that you want to sketch a 6mm line straight down from the end of the horizontal line. Now sketch a 15mm horizontal line towards the left from the bottom of the vertical line. Now from the end of the 15mm line, sketch a vertical line and connect it to the other 15mm line. After this you want to delete top and left lines of the rectangles you sketched earlier. Then you want to sketch three centerlines from the center of the smaller diagonal lines like in the picture. Now you want to sketch lines from the center of the centerline diagonally towards the bottom of the previous diagonal lines like in the pictures. Now delete the diagonal that are above the new diagonal lines you made like in the picture. The next step for the key is to extrude it out 2mm then create a new sketch on the the top of the key. Then from the center of the top left side of the key, sketch a centerline that is 4mm long. At the end of the centerline, sketch a circle with a diameter of 5mm. Exit the sketch and extrude a cut through the key. Next is the fillets, you want to select the top line and bottom line of the left side of the key, and fillet it 10mm. The Next fillet you want to select the three lines at the peaks of the key (as seen in the picture) and fillet them 0.2mm. Now you are done with the key and now we are going to move onto the cylinder for the key to be inserted into.

Step 4: Key Cylinder

The first thing you want to do is sketch a 17.75mm circle on the top plane. Then you want to extrude the circle 35mm. Next you want to select the front plane and go to reference geometry and click on plane. Then you want the new plane to be 8.75mm above the front plane.

After that you want to sketch on that new plane you just made. The first thing for this new sketch is to sketch a centerline from the bottom of the cylinder to the top of the cylinder. Then you want to sketch a 5mm circle on the centerline and smart dimension the circle to be 9.5mm away from the bottom of the cylinder. Next you want to sketch another 5mm circle on the centerline above the previous circle and make their centers be 7mm away from each other. Then you want to sketch another 5mm circle on the centerline above the previous and smart dimension it to be 7mm away from each other. Now you want to exit the sketch and cut extrude the the sketch. The cut extrude should go 13.5mm into the cylinder and 1mm in the other direction. The next thing you want to do is select the top of the cylinder and create a sketch on it. From the center of the circle when you go into top view, create a centerline down and to the right at a 45 degree angle. From the center of the centerline, create a 4mm circle and then extrude it up 7mm. After that you want to select the bottom of the cylinder and create a new sketch. In this new sketch, create two circle. The first circle should start from the middle of the bottom of the cylinder and be 17.75mm long and the second should be bigger and have a 3mm gap between the smaller one. After this you want to exit the sketch and extrude the piece up 2mm. Now create a new sketch on the bottom of the cylinder. Sketch a 17.75mm circle from the center of the bottom of the cylinder and a centerline from the top of the 17.75mm circle down, through the center of the circle, and smart dimension it to be 15.75mm long. From the bottom of the new centerline, create a line that is 2.3mm long with the center being on the centerline. Then from each end point of the line sketch a line up straight up that is 10.7mm tall. Now you want to connect the top of the lines to each other to make a rectangle and delete the 17.75mm circle you made. Next you want to cut extrude the rectangle you just made to be 32.75mm into the cylinder. Now save the part and create a new part.

Step 5: The Locking Bar

For this part you want to sketch a 10mm circle on the top plane, and extrude it out 35mm.

Then on the right plane at the other end of the cylinder, create a diagonal line from the top going to the bottom going at a 45 degree angle. After that create a line from the top of the diagonal line straight down to the end of end of the bottom of the cylinder and create a line connecting the bottom of the diagonal line to the bottom of the line you just made to create a triangle. Now you want to create a cut extrude of that sketch that goes through the cylinder. After this you want to create a sketch on the front plane. This sketch should have a 10mm centerline that starts at the bottom of the locking bar. Then from the end of the centerline, create a centerline straight down that is 5mm long. Next you want to create a new plane that is 10mm from the bottom of the locking bar. On this new plane, create a new sketch that has a 10mm circle on the origin, and a horizontal centerline that goes through the center of the locking bar. Then create a 3-point arc that connects the two points of the centerline you just made and have the arc go down to the bottom of the centerline from the previous sketch. Then create another 3-point arc from the ends of the centerline and goes down to the bottom of the circle. Now delete the 10mm circle, and after that extrude the sketch back, towards the bottom of the locking bar, 3mm. Save the part and open a new part.

Step 6: The Shackle

The first thing you want to do is create a sketch on the top plane of two circles that are 10mm in diameter and 115.4mm apart.

Next you want to extrude the circle out 15mm and on the left one, create a new sketch on the front plane. From the top of the side facing the other cylinder, create a straight line up from the bottom of the cylinder to the top. Then create two diagonal lines towards the center of the cylinder and make them connect. Then sketch a centerline from the point of connection for the two diagonal lines straight over to the other side of the triangle and smart dimension it to be 5.5mm long. Then smart dimension the point to be 5mm away from the top of the cylinder and cut extrude the triangle though the cylinder. Now you want to go to the other cylinder you made and create a sketch on the top of that cylinder. This sketch should have a circle the is 10mm in diameter and has its center being the same as the top of the cylinder. Then you want to extrude that sketchup 29mm. Next you want to create an axis on the smaller cylinder like in the picture. From the new axis you want to create a plane with the first reference the front plane and the second being the Axis you just made. The first reference should be parallel and second should be coincident. After that you want to sketch on that new plane. Create 55mm line straight down from the outside and bottom of the smaller cylinder. Then create a 55mm line straight down from the outside and bottom of the taller cylinder and connect the two with a horizontal line. After that you want to create a line straight down from the bottom and inside of the smaller cylinder and make it 49mm long. Now from the inside and bottom of the create a 49mm line straight down and connect the two 49mm lines with a horizontal line. Now you want to close off the shape so create a horizontal line from the inside of the bottom cylinder to the outside, and do the same for the big cylinder. Now you want to extrude the sketch you just made to go 5mm in both directions. After that you want to create a 5mm fillet with the four lines that go straight down from the cylinders. Then save the part and create a new part.

Step 7: The Shell

Bottom:

The first thing you want to do is create a new sketch and in that sketch, create a rectangle that is 61mm by 80.7mm. Then you want to extrude the sketch out 24mm and create a shell from the top with a wall length of 2mm. Now you want to create a sketch on the bottom of the shell. In this sketch, you want to start by creating a 2mm by 57mm rectangle on the right side of the box that is 14mm from the wall. Then create a 2mm by 2mm square that is 47.6mm from the left wall and 12.5mm from the bottom ball. Next you create another 2x2mm square and make this one 42mm from the bottom wall and 30mm away from the left wall. After that you want to create another 2x2mm square that is 15mm from the left wall and 25.5mm from the bottom wall. Next create a 4mm by 2mm and a 4 by 2.7mm rectangle on the left side of the 2mm by 57mm rectangle with the 2.7 one being above the 2mm one. Then smart dimension them to be 11mm apart and the bottom one be 42mm from the bottom wall. The last rectangle is a 2.7mm by 2mm rectangle that is 30mm from the left wall and 11mm above the 2x2 square in the same column as it. Now extrude the pieces to be 7.5mm tall. Next you want to sketch a 18mm circle on the front side of the lock from the center of the face. Then extrude a cut of the circle 10mm into the lock. After that you want to select the back side of the lock and sketch two 10.5mm circles. One of the circles should have their diameter be 12mm away from the left wall with the other being 7mm away from the right wall. Take the circles and extrude them into the lock 10mm. Top: For the top the first thing you want to do is sketch a 61mm by 80.7mm rectangle. The next step is to extrude it up 3mm and save it.

Step 8: Extracting the Springs

For the springs, you want to unscrew the bottom of the pen, then take out the center part. When the center part is out, take the spring off of it set it to the side. Repeat this multiple times until you have 4 springs then do what you want with the pen. I suggest putting the pens back together without the spring, or keeping the centerpiece to replace pens that have run out of ink.

Step 9: Assemble

To assemble the lock the first thing you want to do is take your springs and top pins and glue them together. After the glue is dry you want to stick them into the slots in the pins and springs holder and glue the bottom of the springs to the bottom of the holder.

Now for the bottom pins, you want to put the smallest in the bottom hole of the key cylinder, the middle pin in the middle hole and the longest pin in the top hole. Next you want to to put the other two springs into the shell of the lock. They go where the blue circles are in the picture. After that you want to add the key cylinder and the springs and pins holder. For this you want to insert the cylinder into the 17.75mm hole on the bottom shell then when that is in the next thing to do is to put the pins holder around it and make sure the pins go into the holes on the key cylinder. Next you need to insert the locking bar. For the locking bar, you want to glue the flat part to the spring above the key cylinder and make sure the outer jut of the locking bar is to the right of the top part of the key cylinder. After that you want to add the shackle. The shackle first be put through the holes on the top of the lock with the longer side going through the hole with the spring at the bottom of it. Then when the shackle is through the hole, you should glue the bottom to the spring. Finally you add the top shell to the bottom shell by covering the top and gluing them together.