For our final project, we were tasked with creating a replica of the LUCIA model, with the flexibility to incorporate our own enhancements. We began by analyzing the existing design and compiled a list of techniques we would use to replicate and improve it. Our main fabrication methods included laser cutting and 3D printing.
Design and Laser Cutting
To kick things off, we made preliminary sketches and moved into digital design using Adobe Illustrator. We carefully measured the original LUCIA model and replicated those dimensions in our files. This design phase went smoothly, but the real challenge came with the laser cutting process.
Fig. 1 Preliminary Sketches
Fig 2. Adobe Illustrator Design
Unfortunately, the laser cutter wasn’t functioning optimally. We had to run multiple passes to fully cut through the wood. Some pieces were difficult to remove from the wooden sheets, so we used an orbital sander to help dislodge them. Eventually, after several attempts and adjustments, we successfully cut all the required components.
Fig 3. The setting for the laser cutter
Fig. 4 Laser Cutting
Fig 5. The unsuccessful laser cutter 🙁
Fig.6 Troubleshooting with the spinning sander
3D Printing
Next, we moved on to the 3D-printed elements. Since metal L-bracket corner braces weren’t available at the OEDK and shipping would take too long, we decided to design and print our own.
Step 1: We measured the original dimensions of the metal angle bracket, including the screw hole diameter, which was 4 mm.
Step 2: Using TinkerCAD, we designed the L-bracket and exported the model as an STL file for 3D printing.
Step 3: We set the layer height to 0.15 mm on the Bambu printer and printed a test bracket.
Step 4: The holes in our first version were too tight for the screws to pass through, so we adjusted the hole diameter from 4 mm to 5 mm.
Step 5: On the second print attempt, the screws fit perfectly through the holes.
Step 6: We duplicated the final design seven times and printed all the required corner braces at once.
With that, our custom 3D-printed L-bracket corner braces were ready for use.
Fig. 7 L-brackets in TinkerCAD
Fig.8 Result
Fig 10. Comparison with the original L-bracket
Following this, we found an already-made design for a clamp that suited the dimensions of the cervixes, and we decided to 3D print it. The clamp was very functional and could be easily modified to suit the minimal differences in the cervixes.
The clamp- G-Clamp fully printable by joehann – Thingiverse.
Fig. 11 The clamp
Completing the model
With the clamp printed and the L-brackets, we were prepared to assemble the model. We used wood glue to glue the appropriate pieces together to create a base (on an angle). Following this with usage of screws and the L-brackets we put all the wooden parts together. The clamp seemed a little bit unstable, so to give it more stability once again we went to TinkerCAD and designed two structures that would hold the clamp in one place.
Fig 12. Supporting structures
Fig 13. 3D print of supports
Fig. 14 All the pieces together
Fig. 15 Assembly of the wooden pieces with glue
Fig. 16 Assembly of the wooden pieces with screws
Fig 17. The whole model assembled
Fig 18. Adding the supports
Fig. 19 Achieving a stable model
The model was done, however, the last step was post-processing. We post-processed the edges with sanding (sandpaper p180).
Fig. 20. Post-processing
Finally our model was done!
Cost Analysis
| Cost Type | Cost | Price | Source | Quantity | Total |
| Materials | PLA filament | $19.99 / kg | Bambu Lab | 19.82g | $0.3962 |
| Screws | $6.89 / 200 pieces | Hillsflatlumber.com | 44 pieces | $1.5158 | |
| Wood Board | $1.33/ piece | Amazon.com | 3 pieces | $3.99 | |
| Wood Glue | $0.8675 / oz | Walmart.com | 1 oz | $0.8675 | |
| Superglue | $0.37/ count | Amazon.com | 1 count | $0.37 | |
| Labor | Prototyping Engineer (Intern) | $17 / hour | ZipRecruiter.com | 10 hours | $170 |
| Overhead | Bambu 3D printer (rental price) | $19 / day | Fatllama.com | 3 hours | $2.375 |
| Laser cutter (rental price) | $10 / hour | University of Irvine | 2.5 hours | $25 | |
| Sanding paper | $ 0.007 / cm2 | The Home Depot | 160 cm2 | $1.12 | |
| Orbital Sander | $ 13 / 4 hrs | Home Depot.com | 20 minutes | $1.08 | |
| Quality control | $27.5 / hour | LinkedIn.com | 0.5 hr | $13.75 | |
| Design | Engineering and Development | $17 / hour | ZipRecruiter.com | 4 hours | $68 |
| Misc. | Waste and Scrap | $0.17/L | Houstontx.gov | 0.2L | $0.034 |
Sum: $288.5
Clean table!
I’m really proud of how this project turned out. It was rewarding to connect the skills and ideas from our midterm project to this final build. A big thank you to my amazing teammates- Xinyin, Wen-Yi, and Katherine-for their support, creativity, and collaboration throughout the course.
Until next time!
