Form 4 Tool Caddy
A user friendly in-machine tool storage system for Formlabs' flagship product
Affiliation:
Formlabs Co-op
Role:
Time Range:
Primary Mechanical Design Engineer
2023
Skills:
Mechanical Design, CAD (Onshape), User Interaction, Product Design, Selective Laser Sintering, High Volume Manufacturing, Snap Fits, Surfacing, Complex Geometry, Aesthetic Parts, Tolerance/Batch Analysis
Background:
This was one of my primary projects while working at Formlabs. The goal was to create a way to store the tools required for maintenance and repair of the Form 4 inside the body of the machine, while creating a seamless and pleasing user experience. In time, the design became focused on producing a caddy that nested into the shell of the Form 4 featuring satisfying snap-fits to hold two hex keys, and a hinged compartment to hold other important tools. The part was also intended to be a showcase of the abilities of another Formlabs printer, the Fuse 1+, so it was to be manufactured using SLS technology at scale.
Images:
My Contributions:
• Assessed product needs and defined a desireable user experience for tool retrieval
• Designed numerous prototypes and assessed their viability
• Refined snap fits and tool insertion ease
• Worked with industrial design department to improve aesthetics and user experience
• Worked with sustaining engineering department to assess batch tolerance distribution and manufacturing optimality
• Assessed potential for creep and degredation for SLS parts
Outcomes:
The tool caddy has since been deployed in every Form 4 shipped to customers. There are now thousands of this part in circulation with Form 4 machines, and I have received feedback from superiors that they are well-liked by management and consumers.