Objective:

Deliver a CAD package for building a functional, yet aesthetically pleasing prototype of a wireless E-ink display. 

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Skills and Tools Used:

• Fusion 360

• Design for FDM

• Industrial Design Sketching

• Wireless Electronics Packaging

• DFA

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Notable Features:

• Clamshell enclosure of uniform wall thickness

• Flush battery door cover optimized for FDM printing

• Heat-set threaded inserts for VESA mounting

• Poka-yoke button design for assembly ease

• Plastic midframe for structure and minimal RF complications 

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Details:

Here's a mechanical design I did for a client who was willing to have the work shared on my site. It's a battery powered, ultra low energy display for things like shopping and to-do lists. When I began, I was provided with a few concept renderings which had already been made.

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The VESA hole pattern and embedded magnets make it easy to mount on a monitor stand or stick to your fridge. The battery door was heavily inspired by the proven, robust design of the TI-84 calculator battery cover.

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The housing was designed with injection molding DFM in mind, as you may be able to guess from features like the uniform wall thickness. One oddity in the design is its size, as this was designed to be visually appealing while still being large enough to fit an entire developer's kit for the wireless module in use. As this project progresses, the housing will likely get considerably thinner.

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Things like the midframe mounting scheme for the display and button structure were inspired by a variety of phones and tablets. 

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The CAD for the fasteners was obtained from the McMaster-Carr catalog.