For an assigment of Industrial Product Design at the Howest, we had to create a pattern maker for glass. After overthinking and designing we came to the conclusion we wanted to create a pattern onto a drinking glass.
The designers of this assigment are
- Arne Warlop Instructable name: Arne_Warlop
- Jay Bytebier Jaybytebier
- Dries Janssens Dries_Jansens
You can check ower designproces on: http://patternmaker07.blogspot.be/
The final draft of the pattern maker project is that we have developed a toolbox where you can storage all the material in. Such as:
- the dremel,
- dremel slang
- pattern maker
So it is a box that you can easily store and carry. The main business of the toolbox is of course the pattern maker. With the pattern maker glass you can give a personal touch by putting on some nice patterns with the pattern maker.
On the video you can see short how it works.
If you have any questions, please contact me.
Step 1: Materials En Tools
What do you need to make the pattern maker?
- Plywood 5mm (3 x 600mmx600mm)
- Plexiglas 3 - 4mm (1x 150mmx150mm)
- Small wood screws
- 1 bolt and 1 nut M6
- Wood Glue
- Small magnets
- 2 small hinges
- 4 lego wheels with corresponding wheel axle
- Brick timber in which the head of the dremel passes
2. Equipment / Tools:
- Laser Cutter
- 3D printer
- Dremel + flexible hose extension and ceramic grinding head
- Drill + clock drilling
Step 2: Laser Cutting
Almost everything is made with a laser cutter machine. We have done this because we had a few errors and tolerances by cuttting it with a sawing machine. With the laser cutter your tolerances are much better and smaller.
You can find the lasercut file in the attachment. In the instructions you can read in following steps what you need to do to put it together. The laser cutter we used was with a range of 600 mm by 450 mm. So all the files are made by these dimensions.
The wood we used is polywood off 5 millimeters and some plexiglass off 3/4 millimeters
We used wood glue to bond it all together.
And some plexiglass off 3/4 millimeters for 2 small things
* if you chose your glass, you need to change the diameter of the support pieces. If you need help in these steps, just contact me.
Step 3: How Put the Pattern Maker Stabbing Together
When you lasercutted all the files, you can start to assembly the pattern maker.
- Step 1
First put all the pieces of the pattern maker and the toolbox separately. That makes it a little bit easier.
Take the base plate, and install the two sides and the back into the slots with wood glue (1).
Step 4: Supports and Rails
- Step 2
Place the supports of the glass into the wooden tray and fix them with wood glue. (2)
If you done this, you need to glue the patterns on each other. So you get a piece of 10 mm thick. It is necesarilly that you put the patterns perfect in place. Use some clips to do that.
Take than the two long flat patterns. You need to install them onto the baseplate (on both extends ) with wood glue. (3)
(4) is the end result of the first subassembly.
Step 5: Pattern Component Part 1
Now the tray is done. So we can make the pattern maker part.
- Step 3
Glue the two sides on the top plate (1). Make sure that the excellence of the side projections are on the side of the bore.
Glue is now the first plastic part at the front of the pattern maker part (with the contact adhesive) (2), and the 2nd plastic part at 35 mm of the first one. (3)
We use two plastic parts, so the pattern maker part moves rectilinearly over the tray.
Step 6: Pattern Maker Part 2
- Step 4
First take a wooden cube of 25 mm at 25 with a minimum height of 20 mm.
Now drill with a drill bit a hole in the wooden piece for the hose from the dremel. The diameter must be 11 mm. Drill then on 1 side of the cube a hole for the nut and the bolt with diameter 6 mm. Do it booth in the middle of the block. You need to place the nut in the hole with some glue. (4)
If this cube is ready, you need to place the hole of 11 mm concentric with the hole on the upper plate.
Step 7: Wheels and Finger Conductors
Place the finger conductors tree on each side. ( see on the picture where you need to place them; green dots).
Place the axle wheels of a lego car into the holes in the movable part.(5)
You can use some glue to make sure that they are fixed. When you have done this, you can install the lego wheels. Or you could 3D print them, if you don't have one. They are in attachment.
If you can't 3D print, than you need to take a piece of wood (10 mm thickness), and make a round wheel with diameter 10 mm.
Now the pattern maker component is ready.
Step 8: Toolbox
In this step we are going to make the toolbox so we can storage the pattern maker.
- Step 5
Start with the base plate and glue the back on it (A).
Next you place one of the sides. Then place the middle plate, so that you have two floors (B).
Now you can place the 2nd side (C). Don't forget to glue them! To assemble this toolbox you definitly need to use clamp, otherwise you will have some problems.
Step 9: Toolbox Extra's
- Step 6
For the lower door of the toolbox, you need to place two hinges (E). So the lower floor can be used as stockage place for the dremel and eventually a glass.
For the upper floor, you just need to place it with glue (D).
At both sides of the toolbox you need to install a handle.
Step 10: Magnets
- Step 7
In this step we are going to place the magnets so that the door and the upper plate close the box.
On the base plate you need to place the magnets on each corner at 6 mm of the sides.
And you need to place a magnet on the inside of the door. And also inside the box.
TIP: hang the first magnet in the inside of the box, but with the other magnet onto it. So that you can check if the magnets are on the wright place. But than also glue on the backside of the second magnet.
Step 11: 3D Printing
- Step 8
In attachment you can find the 3D files to print.
You need to print:
- 6 fingers houlders
- 2 rails
- 1 component to fix the glass. The radius where you need to put the glass in, is the same as our glass we used. So if you chose another glass, you need to chance the radius.
Step 12: Place the 3D Printed Parts
- Step 9
When you printed the 3D parts, you have to place them on the base plate. On the base you can see four holes. These holes match with the holes of the two 3D printed rails. To connect it with the wood, you can use screws and some glue.
Make sure that the rails are open in the direction of the glass.
If you have done this you can place the glass fixer. Normally it passes good between the two rails.
Step 13: Fix the Glass
- Step 10
Now you need to place the glass onto the supports.
Now you need to fix the glass with the 3D printed glass fixer. When the glass is fixed, you need to put a line after the 3D printed component.
At that place you need to drill a hole. You can chose the diameter. But you need to place a pin in it. So you can be sure it passes.
Step 14: Install the Dremel
- Step 11
Now you can install the dremel.
You need to make that the dremel touches the glass. If you have done this, you need to thighten the bolt.
Then is the dremel flexible hose fixed.
Now the pattern maker is complete!
Step 15: Instructions
Your pattern maker is now complete. On the photo's you can see the end result.
In the video you can see the instructions how to create the pattern onto the glass.
I would say GOOD LUCK and have some fun!!