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Original Work/Product Proposal

Introduction and Statement of Purpose:

My original product will be the design of a company logo sign that will be hung in the

front office of the company that employs my mentor. The sign will be made from sheet metal

and will be design as a scaled-up 3D model of the company logo. The company logo is a non-

normal hexagon, with 2 square edges on the bottom and a flat edge on top, closely resembling

the outline of a house. On the front,

the company initials will be cut out of

the sheet, revealing the remaining

layers. The sign will have 4 total

layers. The 1st layer will be raised one

sheet width above the second and will

consist of a border going around the

outside of the sign. The second layer

will have the letter cutouts. The third layer will consist of 22 stars arranged in a cross-diagonal

pattern. These stars, as with the rest of the sign dimensions, will be scaled up from the logo. The

4th and final layer will be the back blue background. In addition to the layers, the sign will be lit

both inside and out. The inside will be lit by blue LED tape lights, where the outside will be lit

by RGB LED tape lights that are controllable. The color and the brightness of the outside lights

will be configurable through an app and Bluetooth or an infrared remote. The sign will be around

30-35” wide and will be hung on the wall using hanging cleats screwed directly into the metal

wall studs.
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The main purpose in this project and product is to learn, as an engineer, how to interact

with clients, coworkers, and shop workers. As a part of the process, I will be presenting my

designs to another employee, and I will be working with her for on the design. She is my client,

and I am making the sign for her. I create designs, she either approves them, or gives me design

aspects that she wants added or changed. I then go back and make these changes, and meet a

second, third, fourth time; however long it takes so settle on a final design. I will then consult

with my mentor and turn the 3D models that I have into the sign itself. In this process, my

mentor is both my mentor and coworker, and the other employees are my clientele. I will be

learning how to establish relationships with them and effectively communicate, which is of

paramount importance in the engineering industry. For example, if there is a communication

breakdown along a chain of people, and 15 inches somehow becomes 50mm, a large problem is

created. The secondary purpose is to learn some of the jargon associate with mechanical

engineering in the field of sheet metal fabricating. Lances, presses, studs, flanges… all these

things I did not know before I began this project, and it is certain that I will continue to learn

more. The third and final purpose is to make a sign for my mentor’s company. At its most

simplistic literal form, the end goal of my project is to walk away with a completed sign hung on

the wall, hanging there (hopefully) far into the future for many to see.

Review of Skills and Research:

The most crucial areas of research are found in the technical jargon of the engineering

field. Without knowledge of basic physics, geometry, and algebra, it can be hard to successfully

design something. In addition, without knowing the limitations of the shop equipment, physical

materials, and hardware, design can be difficult. Since I started my mentorship, I have slowly

been learning some of the hardware, vocabulary, and software that I need to complete my
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original work and final product. To generate the 3D models and drawings that will be sent into

the shop, I will be using Autodesk Fusion 360. Fusion 360 is

Autodesk’s cloud-based consumer version of its commercial

software: Autodesk inventor. Fusion can perform all the tasks that

Inventor can, and in addition, it is more user and cross-platform

friendly. In Fusion, I can open and edit files from inventor, Solid works, AutoCAD, and other

platforms. I also got it free as part of my Engineering class that I am enrolled in at Frisco ISD’s

Career and Technical Education Center (CTE Center). I have spent 6 months with Fusion 360

this year, and yet, there are still some processes and features that I need to google tutorials to find

the answers that I am looking for. Recently, I found a video series highlighting the functions and

features of the Sheet Metal function in Fusion 360. I worked my way through the videos, and

while I was watching the videos, I was practicing creating the designs. From these videos, I

know how to create flanges, change sheet metal rules, join multiple bodies and components, and

change the bend relief parameters. These are all functions and tools that I will need to use when

creating the models for my final product. As of right now, I have a firm grasp of Fusion, but, I

know that I will run into problems in my project that involve processes that I do not know. To

help aid this, I have bookmarked a Fusion 360 video learning series. In in addition to the video

series, I have also bookmarked 2 Fusion sheet metal forms and the official Autodesk help

website. I hope that, with my mentor and these recourses, I will be able to power through any

problems that might arise while I am designing.

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Methodology:

The engineering design process is one that

will be repeated throughout my procedure in the

design of the sign. There are too many variations of

the design process, each caters to the specific design

problem that is being dealt with. The basic 6 step

design process that I learned in my engineering

classes is as follows:

Step1:

- Define the problem: What is the problem? What components/system does it include?

Step 2:

- Generate Concepts: Brainstorming phase… At this point, no solutions are wrong. The

point of this step is to dump ideas into a mental pile. The final solution could be one or a

combination of the ideas that have been mentally recorded.

Step 3:

- Develop a solution: Pour through all the ideas and thoughts that you generated when

brainstorming and start knocking some out via process of elimination. “This solution it

overly complex” and “this solution would cost more money than it is worth”
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Step 4:

- Construct and test a prototype: In my application, in this project, this phase would be

modeling a part and then test-fitting in the other modeled parts. This could also mean

making small mock-ups of a design to see if it will work.

Step 5:

- Evaluate the solution: Does the solution that I have chosen fix the problem? Does it meet

all the design parameters that were set? Is feasible/viable?

AT THIS POINT: If the solution passes step 5, it can move on to step 6. If not… back to the

drawing board (Step 1)

Step 6:

- Present the solution: Present to clients, implement the solution into the systems.

To first start to design the sign, I need to create sketches in Fusion. These sketches will be the

dimensions of the logo scaled up by a factor k. That factor will be determined based on how

large the company wants the sign to be. All other measurements will be based of the k factor and

initial sketches. I accurately measure the features on the logo, I will print a copy of the logo,

ensuring that the print aspect ratio is consistent with the image aspect ratio. I will then use a dial

caliper to precisely measure the features, scale them up by k, and then use the scaled dimensions

to draw the sketch I will create 2 initial sketches. The first will be just the outline of the logo.

The second will the outline of the logo with the cutout letters. I will save these 2 sketches in 2

different files because they will eventually become 2 separate parts. On the sketch with the letter

cutouts, I will then set it to be a sheet of metal. I will also due this on the outline sketch. From
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now on, I will be referring to the letter sketch as Front and the outline sketch as Back. On the

front sketch, I will create a new component and join it to the front face of the AMF cutout. This

will be the border that can be seen around the logo. On the back piece, I will create 2 flanges.

The first flange is on all 6 edges and will be 90 digress straight up with a TBD length multiplied

by factor k. The next flange will be -90 degrees straight out, away from the center, and it will be

the same width as the border on the front piece, which will again be determined by the logo

measurement multiped by the factor k. At this point I need to save both files. This is important to

do always, so I will be saving once every other edit. I now need to create the stars. The stars will

be cut out of sheet metal, and I will need 22 of them of match the logo. The size of the stars will

again be determined by the logo measurements multiplied by the factor k. After I sketch the star,

I will set it to be a solid cutout of sheet metal. Next, I will insert 22 stars into the back sketch,

and arrange them on the back of the sign just as in the logo. After this, so they stay put in the

model, I will establish the body and components as a rigid group. I now need to add lights. I do

not need to sketch the tape lights as I already have the files that were provided by my mentor. I

will join the blue lights to the back of the front piece, and multicolor lights to the back of the

back piece. After this, perhaps the final step for now, is to join the front and back pieces. I will

do this by creating a rigid body. The model is complete, and I’m done with my final product. I

can rest easy until graduation…. NOT.

The initial 3D model is just for show, it is designed simply to provide a concept to the

client. The next phases of the 3D model require actually thinking and careful materials and

fabricating planning. The main problems that I will need to use the design process create are:

- The A: There is a floating piece in the middle of the A. I need to figure out how that

middle “A” component is going to be joined to the rest of the sign.

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- Lights: The double-sided tape that comes standard on the tape lights isn’t all that great.

According to my mentor, it sucks. So, I need to find a way attach the LED tape lights that

does not involve double-sided tape.

- Joints: Not everything can be welded together. I will need to use mechanical fasteners. I

am aware of the McMaster-Carr database where I can browse for mechanical fasteners.

My goal, to make it easier to fabricate and assemble in the shop, is to minimize the use of

welding

- Electronics: Where will I house the control boxes and power supplies for the LED’s. The

power supplies are quite large as they step down from 120VAC to 12VDC.

- Hanging Solution: The sign will somehow need to find its way onto the wall. It will be

made completely out of metal, with the only exceptions being the LED’s and painted

components. So, the sign will be heavy, it cannot simply be hung on a nail. The nail

would be ripped out of the wall and the sign would come crashing to the ground.

- Light Controls: This may also fall under the LED category. The LEDs on the inside fixed

blue diodes that do not need to be controlled. They will turn off and on as the sign is

plugged in and unplugged

- Power Solution: How to turn the sign on and off. I would be tedious and uncomeatable to

have to kneel and plug the sign in every time the sign needed to be turned on and off. I

will need to find a solution to this that is not only affordable but practical as well.

After the initial 3D model is completed, it will be built upon; inserting the solutions above

into the model. The final design iteration of the 3D model should be an exact replica of what the

sign will look like. The next step is to create renderings. Renderings are high definition images

of the model in the environment that it will be in. Fusion generates the environment my setting
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the position and tone of the room lighting. I know what room the sign will eventually be handing

in, so, with that information, I will be able to correctly set the light settings and see how the

materials and LED’s will react to the room lighting. If the rendering come in and there are now

awkward shadows, then the sign is ready to be constructed.

The shop workers, as skilled as they are, will not be able to build the sign based solely on the

3D model and renderings. They need well dimensioned drawings, of each part, from multiple

angels, and a list of mechanical fasteners and weld lines. To provide them with this, I will utilize

the draw function in Fusion. This part of the program allows the user to created dimensioned

plans of each individual part, as well as insert lists of components and mechanical fasteners. It is

here where I can lay down the instructions for welding and fasting, cutting, punching, pressing,

and folding. The format of the plans will be identical to those that my mentor puts thruoguh the

shop, ensuring that all parts are built to specifications. I will also be in the shop during

construction to take pictures and videos of the built process that I can showcase at final

presentation night.

Calendar:

Due Dates:

- Final Presentation: May 18, 2018

- Plans Completed: March 30, 2018

- Design Confirmed: March 15, 2018

- First Design: March 1, 2018

- Project Timeline: February 22, 2018

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Meetings:

- 1st Design Proposal: March 1, 2018

- 2nd Design Proposal: March 5, 2018

- Final Design Meeting: March 8, 2018

- Parts Check Meeting 1: March 14, 2018

- Parts Check Meeting 2: March 19, 2018

- Final Parts Check Meeting: March 22, 2018

- Extra Meeting: March 26, 2018

- Extra Meeting: March 28, 2018

- Files are due meeting: March 30, 2018

Above is a meeting schedule that I have worked out with my mentor. The first 2 meetings

will be only about the design of the sign; what it will look like. The remaining meetings up to the

one on March 30th will focus on preparing plans to be sent into the shop. I have allotted a

significant amount of time to the plans because I know that is crucial to “dot every i and cross

every t.” These plans are what the shop workers will go off when fabricating the sign, and, if

there are any errors, no matter how large, they will manifest themselves in the final product. All

of the plans need to be submitted to the shop by April 1st, as it will take them a while to build

everything.

While the sign is being constructed, I will stop by once or twice a week to check progress

and take pictures for my presentation. During the month of April, I will work on crafting my

presentation and updating my portfolio and display board. Sometime during the 1st week in May,

the sign will be completed. At that time, I will meet with my mentor and we will hang it on the

wall. After that, my final product is completed.

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Materials:

The materials that I will need to complete this project are:

- Dial Caliper: I will use this to measure fine details of the log and scale them up by factor

k. This item will be free as I already ow I dial caliper that I can use on this project.

- Laptop with Fusion 360: I will use Fusion 360 to create all 3D models, drawings, and

plans. This will also not add a cost to the project as I already have a laptop with Fusion in

my possession.

The rest of the materials will be provided by All Metals themselves. Because they are contracting

me to design their sign, they are building it in house and paying for all of it. The materials

include magnets, sheet metal, paint, LED’s, and fasteners. In addition to the hardware, All

Metals has all the equipment and tools necessary to complete the build. I already have a running

list of mechanical fasteners that will need to be ordered if not already in stock:

Weld Studs: 7845A85

- Material: 18-8 Stainless Steel

- Thread Size: ¼”-20

- Length: ½”

Weld Stud Nuts: 94758A028

- Material: 18-8 Stainless Steel

- Thread Size: ¼”-20

- Thread Direction: Right hand

Clip to Sign Bolts: 92620A401

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- Material: Grade 8 Steel (Yellow-Chromate Plated)

- Thread Size: 4-40

- Thread Direction: Right Hand

- Length: ¼”

Clip to Sign Nuts: 90480A005

- Material: Grade 2 Steel (Zinc Plated)

- Thread Size: 4-40

- Thread Direction: Right Hand

LED Control Shelf to Sign Back: 92949A239

- Material: 18-8 Stainless Steel

- Thread Size: 10-24

- Thread Direction: Right Hand

LED Control Shelf to Sign Back: 94785A013

- Material: 18-8 Stainless Steel

- Thread Size: 10-24

- Thread Direction: Right hand

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