Puzzle Cube Challenge Day 1

Today we began the Puzzle Cube Challenge. At the beginning of class, each student was given 27 3/4" wooden cubes. We were supposed to use these cubes to design pieces to a puzzle. Part of the class included the activity of using the VEX blocks to also build models of these pieces. We tried to see how many different combinations we could make using between 4-6 blocks.

5 VEX blocks 

The second part of the activity included our entire class trying to create piece combinations.

VEX blocks stacked to form a cube

We are supposed to use the knowledge obtained from this experiment to create our own cube puzzles. We have started by sketching them on paper, and we will eventually 3D model our pieces using AutoDesk Inventor. I have created my puzzle cube design in my engineering notebook. The entrees include a color-coded mapping of the cube, multi-view sketches, and isometric sketches. I am specifically excited for 3D modeling. I have used modeling programs before, including Inventor, Maya, Google SketchUp, and many more. Hopefully we will be able to start 3D modeling in the next class. 

Optics Museum Project Construction Day 5

Today we were able to glue in the main pieces to our Optics Museum Project. We included the small plane mirror illusion box, and two mirrors. Originally, we wanted to create a concave mirror illusion, where the mirrors' reflections would seemingly project an image above; however, because the delivered concave mirrors were not deep enough, this was not an option. When we ordered the mirrors, we were not expecting for them to be reflective on both sides. This meant that we now had both concave and convex mirrors. We decided to use the surprise to our benefit. We mounted two mirrors on the sides of the box walls. The concave side facing outwards for one of the mirrors, and the convex side facing outwards for the other mirror. This new exhibit will demonstrate the difference between the two. 

Exhibit progress for today

Because of multiple changes in our original project plan, we were required to redesign our orthographic and isometric sketches. Sketches of the new design will be featured in our Purchase List document in place of the old designs. 

Top view of Optics Museum Project

Our next class will be the last day to work on our projects before they are due. We have printed all of our 3D pieces, so it is likely that our next day will be mainly organizing all our material. 

Optics Museum Project Construction Day 4

Today I was able to print the first four small plastic pieces we planned on using in our exhibit. The first few days of trying to print the pieces were relatively difficult. The printer would not warm up to the correct temperature in order to create the pieces. It took over two classes to get to printer to cooperate. 

3D printer in GBS makerspace

When we finally were able to fix the printer, we began by printing two of the four sample pieces to see if everything was on scale. 

3D printer in action

Below are the final four pieces. They are all less than 2 cm in length. For the next class, we plan on printing multiples of these pieces in case they are lost during the exhibit. 

Final pieces

Optics Museum Project Construction Day 3

Today was a day for updating measurements and dimensions. The plane mirror we received in the mail was slightly different than we had expected. Originally, I planned on creating the plane mirror box so that it would be 10 x 10 x 10 centimeters. However, because of the unexpected change of events, these measurements needed to be adjusted. The box seen in the pictures is 7.6 x 7.6 x 14 centimeters. (3 x 3 x 5.5 inches). Here is a link to our project documentation. It includes estimated/predicted measurements to each part of our display. Note that all entrees are subject to change.

Plane mirror box illusion front view

Plane mirror box illusion top view

It turns out that completing this box before we printed the 3D objects was for the better. Now that I have the box's precise dimensions, I know how much space I have to work with. Hopefully our next class will provide enough time for 3D printing. 

Optics Museum Project Construction Day 2

Today was the second day of our Optics Museum construction. For our project, my partners and I decided we would include a smaller wooden box within the large one (see "Optics Museum Project Construction Day 1"). This smaller box will serve as both a container and as an optical illusion. I plan on painting the wood using black acrylic paint, and diagonally inserting a plane mirror. After the plane mirror is secure, I will store small 3D-printed pieces in the box. The combination of the black paint and mirror will give the illusion that the box is empty.

The box's dimensions were based off of the plane mirror we ordered. My partner helped use the table saw to cut the wood pieces into the desired size. Because the walls of this box were only about 10cm x 10cm, wood glue was used rather than nails.

Box for plane mirror (approximately 10cm x 10cm)

I spent majority of the period modeling the small pieces for the plane mirror illusion. I have done 3D-modeling in the past, so designing using AutoDesk Inventor again today was quite enjoyable. Because these pieces will need to fit into the small box, they are each no larger than 3 centimeters.

"Puzzle piece" for plane mirror box created in Inventor

I began with setting the program so that dimensions were marked with metric units. This time, specifically for the purpose of size, I used millimeters. I used the "line" tool to sketch the general shape of the pieces. I corrected the scale by manually entering in dimensions after the basic shapes were determined. Then I used the "extrude" tool to convert the 2-dimensional sketch into the 3-dimensional model, soon to be used in the actual printing of the object. 

"Puzzle piece" for plane mirror box created in Inventor

For the next class, I plan on printing the pieces I modeled. If all goes well, we will be able to complete this portion of the project.  

Optics Museum Project Construction Day 1

Today was our first Optics Museum Project Construction Day. The main objective was to determine the measurements for the exhibit's container, and to cut the board based on these measurements. While most groups decided to use a closed exhibit with four wooden faces, my group and I decided to use an open exhibit with three wooden faces. Our project will not involve lasers, so this design will work well and easily.

The wood boards given to us were approximately 16in x 16in.  It was our job to trim the boards so that they would fit together evenly in a perfect cube. We decided the first board (labeled 1) would be 15.5in x 16in, the second board (labeled 2) would be 16in x 16in, and the third board (labeled 3) would be 15.5in x 15.5in.

We used the table saw to cut out these measurements. We made sure to consider the width of the blade, which could potentially cause a smaller measurement than we expected.

Athanacia measuring up board on table saw

After the boards were all cut, we placed the boards together to see if they fit. Fortunately, our measurements and cutting were both accurate. Next time in class, we plan on gluing these boards together. 

Michelle and me aligning and checking board measurements

Penny Hockey Fabrication Day 5

Today was the last day of our Penny Hockey fabrication. For me, the steps after laser engraving went very quickly. The first thing I did was use the drill press to make the goals. I used clamps to hold down the board as I pulled the drill downwards. 

Me using the drill press

Here is a picture of what my board looked like after I finished drilling the goals. They were both one inch away from the edge.

My penny hockey set after I drilled the goalies

The next thing I did was mark where my defenders would go. With a similar process to marking the goals, I based the defenders' positions off of research done earlier. Here is a mapping of where the marks went.

Penny hockey set after drilling holes and marking defender positions

After this, I was originally supposed to drill where I marked, but the line for the hand drill was too long. To save time, I decided to nail the border in place. Out of all the tools I got to use, the nail gun was the most difficult. It was hard to find a place on my piece where I could grip it tightly. I had to always make sure my hand was at least six inches away from the direction the gun was pointed in. A couple of times, I accidentally inserted the nail too high up, causing it to come through the top of the board. Fortunately, I was able to correct the mistake.

Me using a nail gun for borders

This next picture shows me drilling in the holes for the defenders. I had to make sure the drill stayed perpendicular to the surface I was drilling in, or the dowels wouldn't insert all the way later on. I kept the rule "righty tighty, lefty loosy" in my mind throughout the process. I needed to switch back and forth between right and left rotations in order to drill through the surface or to take the drill out.

Me using hand drill for defenders' holes

I inserted the dowel defenders last -- a fairly easy step. Below is my completed penny hockey project. I wanted to glue the border's outside with pennies, but unfortunately, time did not permit. Either way, my final product was successful.

My final penny hockey set

Lastly, here are some pictures of my engineering notebook. This is a picture of the first two pages, which include my design brief, research, materials list, and tools list.

Engineering notebook research

These pages include my concept sketches. There is an isometric view, top view, front view, and side view.

Engineering notebook concept sketches

The next three pages show my design process. They include pictures that I have inserted in previous blog posts.

Engineering notebook design process pictures

Engineering notebook design process pictures (cont.)

Overall, I had a great time taking part the penny hockey project. My favorite part of fabrication was using the laser engraver, while my least favorite was using the nail gun. I thought that this project was a clever way to give all students the change to use the tools we are provided with. I learned a lot about how to create something entirely new using raw materials, and this will greatly benefit me in future projects.

Penny Hockey Fabrication Day 4

Today I finally got to laser engrave. Below shows what my logo looked like before being printed. I decided to use this logo instead of the one previously mentioned because it seemed like every person I spoke to outside of STEM did not know what a penny hockey set was.

Penny hockey logo I designed 

Here is a picture of the laser engraver setup. It works just like a normal paper printer. I connected a PC to the laser engraver, then copied and pasted the logo into Adobe Illustrator. I adjusted the dimensions in the program so the logo would be centered when it was printed. I also adjusted the speed and strength of the laser to accompany the material it was engraving. Simply select File, Print to send a message to the engraver. The laser engraver is much easier to use than I had expected. I was even able to help classmates who were not familiar with how to operate it.

GBS Makerspace laser engraver 

This is what my vinyl tile looked like once I printed the logo. I purposely designed it so that there would be space on the ends to drill the goals. The back of the tile was adhesive, so I was able to easily place it onto the base board.

Vinyl tile after I laser engraved the logo into it

The next thing I did was mark where the goals and defenders would be placed. I based the positions off of previous research conducted in the beginning of the project. I marked the goals 1" away from the edge of each end to provide maximum playing space. I plan on placing defenders evenly across the board to make the game challenging but not impossible.

Me measuring goalie placement

For the next class, I will use the drill press based off the marks I made. I will also need to nail on the boundaries.

Penny Hockey Fabrication Day 3

Today I planned on laser engraving a logo into the vinyl tile I cut. Below is a picture of the 8.5in x 12in black vinyl tile. While printing, the engraver started producing an unusually large amount of smoke. It filled the entire Makerspace with the stench of burning plastic. The engraver stopped halfway through printing someone's logo. Later we found out that the laser engraver's filter needed to be changed. No one was able to do so at the moment, so unfortunately, laser engraving for everyone in line was delayed.

8in x 12in vinyl tile

Since the laser engraver was temporarily out of order, I worked on completing my engineering notebook instead. I finished my research and determined where I would place the defenders and goals on the set. I also began my concept sketches. I plan on including an isometric sketch using isometric paper, and a front, side, and top view using orthographic paper.

Me working on my engineering notebook

Because of multiple setbacks, the due date of the project was moved back to November 12th. Hopefully the laser engraver's filter will be changed by the next class, and everyone will be able to continue with their projects.

Penny Hockey Fabrication Day 2

Today I got a chance to use the miter saw. The 1" x 1-1/4" common board provided in the previous class is what would be used as the border of the penny hockey set. I marked the 4' board before making the final cuts. I left 1/16 inch spaces between each marking for the miter saw blade. I kept my hand a safe six inches away from the blade as I used it. I used the sander to smooth the wood pieces' rough edges so they will line up when I nail them around the base. Surprisingly, compared to the miter saw, I found the sander difficult to use. Unlike most tools in the Makerspace, the sander does not allow you to use exact measurements. I had to be very weary while smoothing the edges of wood so as not to shave off too much. The pictures following display me using the miter saw and the final common board pieces in comparison to the base piece.

Me using the miter saw

Final common board pieces

The next thing I did was cut the 1' x 1' vinyl tile. Every person had a choice between a white and a black colored tile. I chose black because I thought that my logo would contrast well with it. Here is a sample of what one of my logos looks like; however, I am still trying to decide if this is the one I will actually engrave on the final product.

STEM Learning Community Logo I designed

To cut the tile, I marked the 8.5in point because that's the same width as the base piece. I ran several light passes along the tile with a box cutter to divide it.

In the next class, I plan on completing the project because I do not have an SRT to work on it. I still need to laser engrave my logo into the tile, cut the dowel rod into smaller pegs, and nail the whole thing together.

Penny Hockey Fabrication Day 1

Today we began our penny hockey set fabrication. We have been given a week to complete the project, including building and documenting our progress. The requirements for our engineer notebooks are the same as requirements for Blogger posts.

My design brief consists of the following:

• Client Company: Toys R us

• Target Consumer: Ages 10 and up

• Designer: Katheryn Woo

• Problem Statement: Identifying a unique gift for each of my younger cousins is quite a difficult task.

• Design Statement: Individually design, test, and build a penny hockey set using standard measurements for playing surface to create a fun game for ages 10 and up. 

• Constraints: 

• Individual work must be produced and submitted

• Design using standard measurements for playing surface

• Additional materials must be submitted for teacher approval via annotated concept sketches

• One week time constraint 

Some research included pictures of penny hockey sets other people have created. Here are a couple that I've found. These versions of the project gave me a better idea of what my final product may turn out as. 

"Mike's Wood Toys By Design." Mike's Wood Toys By Design. Web. 01 Nov. 2014. 

"SolidWorks 2012 Penny Hockey Tutorials." Cudacountry. Web. 30 Oct. 2014. 

A few of the first materials given to us today were a 1' x 1' piece if a 1/2" MDF board and a 4' long 1" x 1-1/4" common board. I cut the 1' x 1' boards into 8.5 inch by 12 inch ones. A real hockey rink is 200' x 85', so I was able to calculate the dimensions of my own hockey set. When cutting with the table saw, I made sure to push the stock against the fence with my right hand, and guide the piece with my left hand, giving me a clean, straight cut. The photo on the bottom shows the board after I cut it. 

Table saw

8" x 12" MDF board

Here is a photo of the 4' long 1" x 1-1/4" common board and what it was originally cut from. This is what will be used for the border of the penny hockey rink.

 4' long 1" x 1-1/4" common board

For the next day, I am going to cut the rest of the materials I will need for the final product. If I am able to prepare all the materials at once, it will make it easier for me to put everything together.

Table Saw and Miter Saw

Today was a day dedicated to observing and experimenting with a couple of machines. Everyone received a turn to practice using the table saw and miter saw in our Makerspace. Before this class, I did not know how to use either of these tools. To see how both tools functioned was riveting. While operating the machines, I noted on all safety requirements down to the obvious, such as keeping fingers a safe distance away from the blade. Each student shaved a strip of wood from the stock. Doing this was surprisingly easier than I had expected. With this newly developed skill, I have began forming ideas for future projects.

Makerspace

Glenbrook South's new Makerspace is an excellent way for STEM students to explore their ideas. We have access to the space throughout the day to create anything within the range of our imaginations. Our Makerspace contains machines such as a 3D printer, miter saw, table saw, laser engraver, and many more. Recently, a Brain Bar has been installed, giving us a place to work at during study halls. Based on various articles, I have discovered that schools across the United States have also began to construct Makerspaces. It is wonderful that students are being given more and more opportunities to express themselves. With all the new resources we are now equipped with, many accomplishments will arise.