Prototyping Log

• Horizontal ‘hook’ area was not sufficiently long enough to fit the felting needle
• Identical halves (Meant to be mirror images of each other)
• Holes for screws were too small

• Horizontal ‘hook’ area was not sufficiently long enough to fit the felting needle
• Cavity for tubing was not sufficiently deep enough
• Holes for screws were too small

• Two halves could be screwed together to fit
• Ends were slightly forced apart
• Suggestion: have 6 instead of just 2 screw points

• Screwed together shut
• Tubing and needle stayed in place unless pulled with a lot of force
• Ready to be fit into the cavity of the Main Body
• Looks like a lego brick 🙂

• Screwed together shut, relatively tight
• Use of 8 smaller screws and countersinks to streamline the design

• Screwed together shut, clamped the tightest out of all versions
• Use of 6 screws (2 bigger, 4 smaller) and countersinks to further streamline the design

• 8 screw holes instead of 6 so it’s more secure

• Tubing cavity is too narrow
• Rectangular cavity is too shallow
• Attachment points (‘mickey mouse ears’!) were out of alignment to the piece that we would secure to
• Two attachment points are insufficient to support the Main Body
• The holes for the screws to secure the two halves together were not the right size
• The protruding screws prevented the attachment of the Main Body to the 3D printer
• PTFE Lube should be added to the inner cavity to reduce friction further
• Need to add the screw points for the attachment of the Yarn + Needle Feeder

• Poor fit with Connector Mk IV / Good fit with Connectors Mk V & VI
• Poor fit with Feeder Mk III / Good fit with Feeder Mk IV
• Black printer filament seems to be smoother than red
• Top left screw on cover (Red) cannot screw down properly
• Can attach onto the 3D Printer’s moving piece
• Feeder can attach onto the back of the Main Body

• Removed the grooves due to streamlined design of newer Connector versions
• Connector moves much smoother than before
• Added a tubing-main body connector piece at the top of the front cover to fix the external tubing opening to the top of the main body
• Back piece was also reprinted to have grooves removed

Back Piece (Printed [#24] 4 July) (Piece in white)

• Different mode of attachment for the Yarn Feeder to the back piece
• Added vertical tube to side of piece for the yarn wool to be led to the Yarn Feeder

• Adjusted vertical spacing between bottom of the Main Body’s main cuboid body and the holes for attachment to the Yarn Feeder Mk VI

• Counterbores for attachment to the yarn feeder were not right — broke off
• Screw bore (protruding piece on the left, as seen in this image) for attachment to the 3D printer piece was not in the right position

• Horizontal ‘plank’ area that allows for attachment to the yarn feeder made thicker to allow counterbores to print properly
• ‘Ear’ screw bore was moved to the left by about 0.5mm, now fits perfectly

• Removed counterbores (for attachment to the Yarn Feeder) as they kept breaking off

• Worked out well when tried out with needle (manually)
• Meant to just be a prototype to confirm that we want a similar model for our final piece

• Needle guiding tube is too tall; the needle is unable to reach the end of the tube when we need the needle to be able to stab through
• Wool yarn feeding tube is too narrow; the threader got stuck at the fork
• Screw points for attachment are missing

• Wool yarn thread can be threaded through the wool feeder
• When attached to the Main Body Mk II, the Connector is able to move up and down, but the needle cannot stab beyond the Feeder base

• Backing (beyond screw attachment points) was too high, interfered in attachment to Printer
• Sawed off the top part of the backing
• Able to be attached to the Main Body
• Needle from Connector was able to stab through beyond the Feeder base

• Acrylic base so we can better study whether the yarn is adhering to the felt
• Modified guiding Y-tubes
• Backing height is adjusted to the sawed height of Mk IV

• Changed the point of attachment
• Surface area between felt and Yarn Feeder is now minimised
• Adjusted the guiding tubes shape
• Issue: Suspected that the base area friction drags the yarn along, preventing it from adhering to the felt properly

• Surface area between felt and Yarn Feeder (base area) is further minimised
• Opening through which needle can stab through is further minimised (2.5 mm)
• “Nozzle” type opening rather than a flat cylindrical base
• Issue: Yarn still not capturing at the edges

• “Nozzle” type opening
• Opening through which needle can stab through is further minimised (1.5 mm)
• Issue: Opening is too small to thread through

• “Nozzle” type opening
• Increased needle opening size to 2 mm
• White print seen on left is print 1, we re-reprinted it with black (print 2)

• Backing is shortened so the rectangular piece no longer touches the yarn as well; only the “nozzle” touches the yarn now

• Reduced needle opening size to 1.75 mm

• Reduced the yarn catchment tube height
• Later, Tony chopped off the nozzle piece so it’s a flat base, with an upright cone depression on the inside; now it feeds much better

• Removed nozzle
• Shorter yarn catch height (0.2 mm)

• From Yarn Feeder Mk XII, removed nozzle area

• Test print to check the alignment of the bores for the screws; successful, except for one bore
• Able to fit LA and LA was able to function
• Stopped printing halfway due to the print product becoming crooked

• Frame is bent
• Holes were in the right position and of the right size
• Height is too short; piston movement obstru
• Stepper motor fits
• Able to adequately sup
• cted by table

• All holes are alignedport the LA when attached to the aluminium frame
• LA piston is able to move without obstruction

• Does not fit nicely on piston head ledge

• Sits nicely on piston head ledge
• Can be screwed tightly over piston head
• Issue: Cavity left to fit over the piston head is too spacious; it can move from side to side too much (possibly causing LA to jam?)

• Sits nicely on piston head ledge
• Minimal horizontal movement as cavity size has decreased
• Almost perfect fit
• Cavity to allow large screw to run through and secure through the hole of the piston head slightly too big

• Lacks square base
• Too tall
• The hoop was too big for the outer wooden hoop to secure over it; next one has to be just slightly smaller

• Can be clipped onto the printing bed
• Secures the cloth in place for embroidery
• Sufficient depth for needle to stab downwards

• Rectangular to fit an even rectangular styrofoam base

• Does not fit (Readjustments needed)
• Would work with reciprocating saw unit if we use it
• Possibly buy a proper metal one instead of printing

• Holes for screws were misaligned by 6 mm
• Need to be aligned to the grooves of the aluminium profile

• Printed out of alignment; readjustments needed

• Adequately holds aluminium profiles together
• Horizontal width over the top of the aluminium profile is too long
• Prevents the alignment of the Profile-Tubing Connector Mk I directly over the LA
• Readjustments needed

• Adequately holds aluminium profiles together
• Horizontal width is shorter
• Allows for alignment of Profile-Tubing Connector Mk I over the LA piston head

• Adequately holds aluminium profiles together
• Horizontal width is shorter
• Allows for alignment of Profile-Tubing Connector Mk I over the LA piston head

• Too small
• Screws are unable to screw in properly

• Shorter (3 cm vertical height) 3-faced piece

• Taller (4 cm vertical height) 4-faced piece
• Fits between horizontal aluminium profile and LA Mount for better support

• Fits perfectly onto the aluminium profile
• Adaptor piece with tubing fits into hole and can be secured onto it well
• Issue: Hole is not perfectly aligned over the head of the LA

• Hole adjusted to be more in line with the LA (Notice the shift nearer to the corner of the bracket)

• Hole adjusted to be more in line with the LA (Notice the shift nearer to the corner of the bracket)
• Reprinted on 17 July with light pink filament due to Print 1 breaking

•  Made out of aluminium profiles and spare brackets
• Friction between metal and connector may be causing it to jam

• Tubing is able to clip in very well; tubing is smoother with less friction
• Tubing holding plane should be 10cm long instead of 8cm
• Currently, the tubing plane would be positioned too low with respect to the connector piece it is meant to stabilise; need to move it upward

* We were able to overcome these issues without designing a new piece, though we are not using it in the same orientation as we had intended to anymore. 

•  Holds the stepper motor in place
• Attachment to the top horizontal frame of the Ender 3 3D Printer
• Needs a metal coupler to further connect to the yarn spool