Below is my initial sketch. While sketching, I thought a lot about how the adapter would lay (straight, standing up, curved), how the lid would work (sliding, inlay, hinged), and how to incorporate a clip. It was tough because I had to "think" like the 3D printer, since it obviously wouldn't do hinges of any sort easily and definitely not a clip that had to flex. It was tough because I wasn't really sure how the materials would react or withstand certain pressures.
In the end, I decided to go with a sliding lid to keep it simple but loved the way the adapter laid in the case while curved. I decided to go with a store bought metallic clip that I can easily screw on after it was printed. In hindsight, I should've tried to 3D print the clip because the PVA had much more flex and strength than I originally thought.
I looked up a bunch of pre-existing designs and learned from their disadvantages. Mostly, they were either too big or designed to be permanently affixed. I used those cons to my advantage and crafted a case that was perfect for what I needed it for.
I also looked into miniature craft and container designer. I considered different types of lids but eventually went for a sliding lid for simplicity sake.
I went for a very minimalist rectangular design for two reasons. Partially because I love the minimalist style but also to keep it basic since this is my first 3D printing project.
I decided to render my case in a neutral setting because the white plastic looked best in this light.
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.
