After the Sketch Model presentation was done for the condiment cap and zero-waste pump dispenser, we were told that both ideas were good choices to pursue. We decided as a group to go with the condiment cap, and since then, we've been coming up with ideas and fabricating them.
The past few weeks have consisted of prototyping and testing. Many prototypes have been made by different members of the team and tested with a Heinz-brand ketchup bottle, with varying results. The more recent tests have resulted in less water making it through the cap compared to previous ones, though water makes it through nonetheless - as we have identified this as a critical function of our product, it is something that must eventually be resolved.
The past few weeks have consisted of prototyping and testing. Many prototypes have been made by different members of the team and tested with a Heinz-brand ketchup bottle, with varying results. The more recent tests have resulted in less water making it through the cap compared to previous ones, though water makes it through nonetheless - as we have identified this as a critical function of our product, it is something that must eventually be resolved.
Those 3D-printed in green were the more recent prototypes, and those in blue (and one in black) were the first prototypes, which the recent models were built on. We determined that having a lid should be a critical function, as it would prevent the drying out of the ketchup (and potentially, resulting in the cap opening getting plugged up), so one of the recent prototypes features one.
During production, we ran into problems with the 3D printer. Early on, they operated well, but around Week 7, two of the three printers became inoperable. With more students beginning to use the printers, we became more pressed for time as well. Thankfully, they were eventually repaired, but even then, some of our prototypes were not produced well due to how they were oriented for the print.
During production, we ran into problems with the 3D printer. Early on, they operated well, but around Week 7, two of the three printers became inoperable. With more students beginning to use the printers, we became more pressed for time as well. Thankfully, they were eventually repaired, but even then, some of our prototypes were not produced well due to how they were oriented for the print.
In most cases, there were but 1-2 ideal ways to position the parts, some of which printed without issues, while others were not so fortunate. Particularly, empty areas beneath the cap that were just above the printer's buildplate experienced problems; even with support material added, those areas became 'stringy' rather than smooth. Take, for example, the image to the left - this part was printed upside-down, opposite the current orientation in the photo. The depressed region meant for the lid had to be supported by a mesh support, but even with it in place, the surface was still printed very roughly. We had to reprint parts like this, where the imperfections impacted functionality. We played with the orientation to see what worked best. Other times, the printer would flat-out compromise a print for one reason or another, like not putting down solid layers of material when it was supposed to. |
With Week 10 being Spring Break and Week 11 being the "Critical Function Science Fair," the prototypes must be ready before we are off for break. With that said, during our last lab meeting (Week 9), we created a rough chart that we will follow for the remainder of the semester.
We determined that we would stop making major changes to our designs by Week 14 so that we don't undermine our efforts moving forward - this cutoff will allow us to focus on improving fewer aspects rather than trying many different ideas. The final prototypes must be ready by the end of Week 15, which begins April 18th.