Part 6: Choosing Materials And Bringing Online Parts To Your Product

Complete Product Design From Home A Design From Home - Solar Light
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Transcript

Let's go ahead and put these screws into place. If I just bring them up to about that point and let's change the opacity on the solar cell holder just to see if that's everything is looking good right now. A solar cell holder at the top piece is definitely going to have to be put on at a certain angle when it's actually assembled but that's okay. Because these tabs that we created me to clear the, you know the point where the bad sits. So we hit ok there. Let's rotate it a little bit more.

So right there and so now it looks like it clears quite well. Let's make our light cover visible. Let's get rid of object visibility if we get rid of some of these origin axes and planes and points just to make our drawing a little bit more easy here. Make those set screws visible so that looks good. Let's take our LED as well and Activate that. So we can drill some small holes for the wires of the LED to fit through.

And that's going to come right through the center of that piece, it's going to clear the battery looks like it's gonna clear everything just fine if we go right through the center. let's right click on the LED choose move just to be able to move this and a little bit more of a precise way. There we go. Let's hit OK. There we go. So we have our LED, placed within our clear globe here.

We have our electronics enclosed, so they're not going to be exposed to elements. Now we need to figure out what to do for the ground stake and we know that we're ultimately going to have to attach it to our top pieces here. So again, For the ground steak, first of all, we can talk about material and how we would manufacture it or if it's going to be a premade part. So back to the same questions that we want to ask in this design process every time. So we can ask what our design constraints are for this ground steak, it definitely needs to be strong enough to stick into the grass. So it needs to have a certain strength.

This ground steak is again going to have to be corrosion resistant. Because it's going to be out side. We want it to be somewhat light weights, I would say that we don't want to, I probably don't want to use you know, stainless steel that would be a very heavy metal for a solar light. But we have some other options here that we can talk about. So again, first we're going to ask ourselves, can we buy this ground stake pre made, if we can buy a pre made we we might be able to get it cheaper than if we can Custom make the steak. If we can't buy it pre made, then we have to talk about custom making it out of some of these different combinations here.

I think it might be possible to get this ground steak pre made to order or something like that either from a local store or from online. Because ground stakes are very common for landscaping for other types of lights. They're common for gardens for different garden applications. Ground stakes are pretty common. So we might be able to find a good ground stake in terms of the material we're looking for. We want it to be lightweight.

We defined some of our design constraints. And we want it needs to be corrosion resistant. So in terms of Steel's we're looking at aluminum would be corrosion resistant stainless steel would be corrosion resistant and titanium of the four that we have talked about, and of those stainless steel we said would be too heavy. Aluminum is definitely a potential option for a ground stake. We could also use plastic might be another option. So let's see if we can find this ground stake online.

So this is where we can go to a search engine. And we can search Google for you know, just ground stake. Try some different options and see what pops up. Right here for example, weatherproof ground stake from Home Depot, which is a common hardware store in the United States. Here is a ground stick with a thread on it so that we can possibly make that in some way with a piece to our acrylic tube. This is a die cast construction.

So it was basically made from a mold of course, and I'm not sure what type of material it is yet. It looks like it's metal, of some type. And I don't believe it says the type of material on here. But nevertheless, this is something that could work for us. And we head back. Here is a landscape accessory ground stake.

This is ABS plastic, which is one of the common plastics that we have talked about. And this was most definitely a product that was you know that a mold was created for this part, so that it could be mass manufactured. When we're developing prototypes. We haven't talked about using plastic injection molding, which is, you know, most likely what they used for a part like this because it cost a lot of money. It's not an inexpensive method of producing a prototype. But it's definitely something we can do at home.

But anyway, this is a an ABS plastics. So this so it sounds like we should be able to it's common to use a plastic for ground stakes and we should be able to find something similar to this we just need to be able to make it with our Acrylic plastic. Okay, so after some searching, I found a good ground steak. That should work for us on Amazon. And this ground steak has a it's made out of plastic and it has a threaded piece on the top of it that we should be able to make our acrylic tube to. And then to be able to bring this into our CAD model when we're getting premade part likes parts like this from manufacturers.

So again, sometimes manufacturers provide a CAD model for you if they don't a lot of the times. You can email them, you can ask the manufacturer for a CAD model and they might send it to you privately. A lot of manufacturers just released their CAD models of their parts online for you. And you can just straight download it. In this case when you're ordering off of Amazon, you probably not going to get a CAD model. And so hopefully the dimensions are specified or at least some of them are specified to at least the degree that you can draw it in CAD well enough to be able to visualize, you know, everything that you will need to be able to visualize clearances, and everything you would need for your CAD model.

So we're given some product dimensions here. And then we need to know the size of the thread on the plastic stick. So I went ahead and drew the plastic safe that we found on Amazon in fusion 360. So let's go ahead and pull that In. So we pull in this plastic steak, we had to draw this from scratch the best we could with the dimensions that we were given off of Amazon. And let's pull that down a little bit.

Right click okay. let's right click and break the link. So now we have a plastic stake in our model with a threaded top, this is a half inch diameter. On the top of this let's double check, half inch diameter. So we need to meet this half inch thread with this acrylic tube so we go Back to our common questions. Again, we asked First of all, would we be able to find a premade part for this.

So I'm gonna have to couple from a half inch thread to a three inch diameter, which is a pretty big couple, it's definitely possible, I think we could find those are some pretty standard dimensions the inside of this tube is exactly three and then this is a half inch, a half inch thread, we should be able to find the part that would do that for us. But I think we would have to use we would most likely have to use multiple parts and it wouldn't be too pretty or too efficient to use multiple couplers since it's a pretty large difference in diameter from half inch to three inches. But we should be able to pretty easily make a custom part that will join these two now In terms of the material for that custom part, this is plastic. Plastic, of course, is an option for us here.

And since we have cylindrical shaped pieces we can, what we could do is we could start with a solid cylindrical rod of a plastic would be a good option, we can simply tap a hole in it to mate with our bottom plastic ground stake. And then maybe use some set screws for the top as we did to mate with the battery holder to find some stock material. Again, let's use McMaster and let's go to the homepage and go to raw materials. We're going to want a plastic. Let's start with a rod. And as we mentioned, Delrin is a really great multipurpose plastic.

It'll work and a lot of applications for us. So let's just choose Delrin. And this is just a solid rod, we're looking at a three inch diameter D, here is diameter, so three inches. So it looks like we should be able to start with a should be able to start with a three inch diameter cylinder of Delrin. And make our parts from that. And that should work really well for us.

And let's see if there's a CAD model here. When it's, of course, going to be very easy to draw this in CAD. And so this is what it would look like. And there's no CAD model. So let's just quickly draw that if we go to assemble a new component, and let's just call it a coupler hit OK. And let's go ahead and try that. Create sketch, I need to make my origin visible.

Let's choose that plane. And I also need to make my sketches visible. This can be a little bit confusing some times I go to sketch sketch dimension and that needs to be exactly three actually to fit inside of the acrylic two, we want to go slightly below three. Let's do what we did before. Let's go to create extrude and pull that up a certain distance just looking at this here. Do I say like, just point, point six, five.

Let's go ahead and activate our assembly and let's pull this into place. Let's go to assemble joint and we want to cylindrical joint that part to that part. Looks good, hit OK. Pull this into place. Let's also make a joint for our ground stage. So let's choose That part and that part.

And for now let's just make that a cylindrical joint. Later on, we're going to want to change that to a rigid joint. Now to connect this plastic piece to our acrylic tube, we can use some set screws again, like we did above. So we need to make some new holes. I could actually so let's go ahead and just isolate this light cover and activate it. And then we should actually be able to go into the same exact sketch and just add two more holes here.

And so let's just go to sketch circle. And I'm going to draw a circle and dimension it's the same as what we used above which was point one, five. And it's point two from the edge. Let's start with that. It's already at point two. Let's stop the sketch and make sure our sketches are visible.

We click on it to make it visible here. Now I want to create an extrude again, I'm going to click on that and we want to do a symmetric extrude. I can't quite remember the distance Since that we extruded last time let's check should be able to edit this it was 1.625. So we go to create extrude to do this again. And let's do symmetric at 1.6 to five. activate our assembly and with the light cover, let's isolate it and it looks like wire hose showed up here.

Let's use the same set screws

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