For our midterm project, my teammates Kyler, Alejandra, and I tackled the challenge of designing a 3D mechanical model using only 2D fabrication techniques, such as vinyl cutting, laser cutting, and water jet cutting. Inspired by Houston’s deep connection to NASA, we set out to create a rotating model of an astronaut on the moon with an orbiting rocket, powered by a dual-gear hand crank. This intricate project brought together our skills in design, prototyping, and problem-solving, showcasing the power of teamwork and perseverance.

Vision and Initial Design Concept

Houston’s legacy in space exploration naturally led us to envision a model celebrating the moon landing. We imagined an astronaut planting both American and Argentinian flags on the moon, with a rocket smoothly orbiting around him. To bring our concept to life, we devised a dual-gear system that would allow the astronaut and rocket to rotate in opposite directions. This design required careful planning to create a two-tiered base that housed both gear systems beneath the surface, enabling our hand-cranked mechanism to function seamlessly.

From Concept to Digital Blueprints

After finalizing our concept, we transitioned to the digital design phase. Using Adobe Illustrator and CAD software, we meticulously crafted layouts for each element. To generate the gears, we used an online gear generator, which allowed us to tailor the specifications precisely for smooth rotation. Every detail needed to be planned digitally before prototyping, so we took extra care to ensure accuracy at this stage.

Prototyping: First Steps and Challenges

To test the design, we initially used cardboard as a low-cost material for prototyping. Our first model revealed some scale issues, prompting us to adjust the dimensions. Unfortunately, a fire incident briefly shut down the laser cutter, forcing us to pause. As soon as it was available again, we resumed testing and moved on to sturdier materials, gradually refining the model with each iteration.

Precision and Rework: The Path to a Perfect Fit

Achieving a precise fit for each piece presented one of our biggest hurdles. Once we began cutting the actual materials, some parts needed resizing due to minor misalignments, something we wished we could have seen when cutting on cardboard. Nonetheless, several rounds of adjustments later, we had a rough version of our model, allowing us to confirm that all the mechanics worked together as envisioned. We then focused on refining the components for a cleaner, more polished final product.

Assembling the Final Model

In the final stages, we concentrated on perfecting the assembly, incorporating a custom name tag, and using the vinyl cutter to add flags. We also used a water jet cutter to include a metal element (the turning handle), enhancing both durability and aesthetic appeal. This stage was all about precision—we learned about the importance of ensuring that each part was aligned and functioning smoothly before doing any permanent changes to the model, such as applying strong wood or attaching two pieces together. 

Reflection and Cost Analysis

Completing this project was both challenging and rewarding. It taught us the importance of collaboration, persistence, and adaptability. Each step, from brainstorming to overcoming technical obstacles, allowed us to deepen our understanding of design and fabrication.

I am happy about the final result, but in this assignment more than any other one, I was aware of the costs it implied: from the usage of material for the different iterations to the time it took us to actually get the job done, it was impossible to ignore what it took for us to get here.

Detailed Cost Breakdown

To evaluate the project’s cost, we accounted for materials, labor, and facility time. We sourced materials from local suppliers like Home Depot and Joann, totaling about $26.50. Labor costs and machine use were significant expenses, with facility time for the laser and vinyl cutters adding up to a considerable portion of the budget. Here’s a breakdown of the main costs:

 

Cost Type	Item	Price	Source	Quantity	Total
Materials	2’x4’x3/16” Board	$12.99	Lowe’s	1	$12.99
	Vinyl Sticker Roll	$6.49	Michael’s	1	$6.49
	Aluminum for Handle	$24.99	eBay	1/6	$4.17
	Wood Glue	$3.50	Walmart	1/10	$0.35
	Epoxy	$7.99	Amazon	1/10	$0.80
	Superglue	$4.29	Target	1	$2.15
	Wood Dowel	$1.50	Home Depot	1	$1.50
Labor	Workshop Operator	$15.00/hr	Payscale.com	1 x 2 hrs	$30.00
	Prototyping Engineer	$12.00/hr	Indeed.com	3 x 4 hrs	$144.00
Overhead	Facility Costs (Machine Time)	$80.00/hr	MachinistGuides.com	4 hrs	$320.00
Design	Engineering and Development	$30.00/hr	Glassdoor	3 x 1 hr	$90.00
Iterations	Re-cuts and Adjustments	$12.99	Lowe’s	2	$25.98
Total Cost Estimate					$606.62

It is important to note that, if a pro had handled the production, things would have run much smoother, and costs would have been much lower. With more efficient work and way fewer re-cuts, this model could come out to about $246.63:

• Labor: $30 (approximate)
• Facility Costs: $160 (less time on the machines)
• Design: $30
• Materials & Assembly: Same as the single-unit costs, but without the extra for all our trial-and-error.

With this side note, we can see how the mid term project really shows the cost of learning by doing—between figuring things out, waiting on machine time, and working in a shared space with other beginners, every lesson added to the price.