Headset Hand
This was the final project in Design and Manufacturing (ME 103). The goal was to design and manufacture a high-quality product using the manufacturing techniques in the class.
Overview
An arm cast out of aluminum emerges from a cherry-walnut composite base. The Headset Hand was designed to be an elegant sculpture that blends seamlessly into my desk setup.
Creative Direction
When designing the project, the idea of emergence became central. The final design is reminiscent of whales leaping out of the water and hands emerging from the ground. With this, the arm needed to be connected to the base in a way that it appeared to be coming out of it.
Circles are another key design element. The concentric circles in the base resemble the ripples coming from an emergence. Additionally when a headset it on the stand, the system resembles a gyroscope, with circles in the xy, yz and xz planes.
Design Features
To accomplish the image of emergence, the arm is attached via fasteners at the bottom of the arm, invisible from the top.
In order for the arm to be sand-casted, the sides of the arm were drafted ten degrees. To avoid shrink, the thickest cross section of the arm resembles an I-beam.
Manufacturing Process - Arm
A pattern board was created by attaching two 3D-printed halves of the arm onto a board of wood. Copious waxing, bondo, and sanding followed in order to have a smooth board. I then rammed up and sand casted the arm out of aluminum. I machined the bottom flush using the mill, and then drilled and threaded four holes (1/4-20 threads). I grinded off the flash and sanded the front/back of the arm smooth while leaving the cast finish on the sides.
Manufacturing Process - Base
A circular jig on the bandsaw was used to cut two circular stencils for the inner and outer pieces. A router was used to cut the square insert into the inner piece as well as the large circular cavity of the larger piece. A chisel was used to take out corners and do some detail work to ensure a snug fit. The pieces are attached via a press-fit and some wood glue. Clearance holes were drilled using a drill press. The base was sanded and finished using boiled linseed oil to bring out the wood’s natural beauty. Rubber feet on the bottom of the base prevent the fasteners from scratching the desk.
Materials
The arm was cast out of Aluminum-6061 in order to optimize both cost and mass. The wooden base is made out of two hardwoods, cherry and walnut. Stainless-steel fasteners were used to attach the base to the arm. Rubber feet were glued to the bottom of the base.
