Process & Procedure

After sketching my design on paper, I took a pair of calipers and got extremely detailed dimensions. I opened up fusion and modeled the adapter itself to start. This way, once I got the adapter modeled, I can just build up a case around it. This approach worked great and allowed me to really understand the space and how the adapter fits into it.

After I sketched the overall case for it, I extruded it and filled in the base with a patch which was later thickened. I added fillets to make putting it in and taking it out a lot easier. Also, so it wasn't so harsh in your hand. Then, I tried a number of different lid designs but ended up going with the sliding lid. I modeled a small rail for it to glide into and modeled the lid separately so it wouldn't stick together while being printed.

After the first print, I realized that I made the fits were WAY too tight and I didn't account for a large enough tolerance between objects. I also forgot to add supports, so it started to droop into the rails and stopped the lid from smoothly sliding. Additionally, I didn't account for the thin base the 3D printer automatically adds to your work, which added an extra 0.2 mm to the overall thickness. So, I went back into the model and looked up different types of engineering fits to get the fit I needed.

Above: the first failed print--too tight in too many places.

After the second print, everything fit A LOT better but one of the parts still didn't fit quite right and I realized I didn't add a finger hole to use when taking the adapter out; it was just getting stuck inside! Plus, I made the little grip points on the lid much more prominent so they used friction with your finger to help you open the lid.

Then, I was really, really hoping to do a third print (and I still will!) but unfortunately this happened:

So, there's no way I could have it done for the deadline! And I'm sure the fit, design, and motion of placing it/taking it out will be perfect.