ENGI 1030 – Machine Shop & 3D Print Report (Steps 6 & 7)
Step 6: Prototype Assembly & Testing
Below are the results of assembling and testing two main parts of our 3D-printed
phone stand prototype. These observations helped guide improvements for
future iterations.
Part 1: Phone Stand Base and Support Arm
- Assembly Details: The base was slotted to accept the angled support arms
using friction-fit joints. The backrest held the phone at a comfortable viewing
angle.
- Testing Outcome: The friction fit worked well initially, but after repeated
assembly/disassembly, the joints loosened slightly.
- Redesign Decision: We decided to add a shallow notch or a locking tab to
improve joint retention.
Part 2: Rotating Holder Arm
- Assembly Details: This component includes a curved clamp with a pivot point
(R0.536 radius) and fits into the side of the base with a fastener.
- Testing Outcome: The rotating part fit well but lacked locking friction, causing
unintended movement.
- Redesign Decision: Plan to introduce either a friction washer or a small snap-fit
bump to allow adjustable but stable positioning.
The figures below show the hand sketch and CAD model of the prototype parts:
Figure 1: Hand Sketch of Phone Stand Design
Figure 2: Onshape CAD Model of Adjustable Holder
Redesign Decisions Summary:
Based on the prototype testing, we identified two key areas for redesign. First,
the friction-fit joints on the support arms became loose after repeated use, so we
plan to incorporate locking tabs or notches for better joint retention. Second, the
rotating holder arm lacked friction, which led to unintentional movement. To solve
this, we will explore adding a friction washer, snap-fit features, or texture to the
contact surfaces to improve stability. These improvements aim to enhance both
the durability and usability of the final design
Step 7: Machining Plan Using Aluminum at MUN Machine Shop
If the phone stand were to be manufactured using aluminum and mechanical
fasteners instead of 3D printing, the following tools and workflow would be used
at MUN’s Student Machine Shop:
Tools Required:
- Bandsaw – For rough cutting aluminum to size
- Vertical Milling Machine – For flat surfaces and slot features
- Drill Press – To create clean, accurate holes
- Tapping Tool – For adding M3 threaded holes
- Deburring Tool / File – To remove burrs and smooth edges
- Calipers / Micrometer – For precision measurements
- Clamps / Vise – To secure parts while machining
- CNC Milling Machine (Optional) – For complex curved parts
- Screwdrivers / Allen Keys – For final assembly
Manufacturing Steps:
1. Cut aluminum blanks to approximate size using the bandsaw.
2. Mill base and arm components to final dimensions using the vertical mill.
3. Drill pivot and mounting holes using the drill press.
4. Tap holes where required for screw threads.
5. CNC mill any curved or complex features like the circular clamp.
6. Deburr all edges and surfaces.
7. Verify dimensions using calipers.
8. Assemble parts using M3 bolts and tools.
Figure 3: Full Assembly View of the Phone Stand in Onshape
Figure 4: Engineering Drawing with Dimensions and Material Details
