Snake Robot

Final product with cup.	Final product.	Easily hangs from lanyard in many configurations.
Holes in handle decrease weight and vertical stiffener allows it to be put in the bottom of a backpack without fear of damage.	Initial concept drawings for cup handle	Initial concept drawings for cup handle. The focus for this design is low weight and mechanical robustness.
Narrowing down design attributes.	First paper prototype	First paper prototype after bending to shape. Note incorrect bottom radius.
First paper prototype. Also note excessively large hoop diameter, which makes the part larger than it needs to be.	New concept for added vertical stiffener, one of the changes after the first prototype. This made manufacture more complex but increased the strength of the product.	Second paper prototype, with vertical stiffener added and minor dimension changed for proper fitment.
Stiffener too short. This was lengthened before the first acrylic part was cut. Handle is also too long which creates a tendency to bow up at the bottom.	Using the paper mockup to select approximate diameter for acrylic bending jig.	Press fit too high, causing crack. Decreased from .010" to .005" for second part. A few bubbles also popped up from too much heat.

Cup Handle

For this assignment, I was tasked with designing and manufacturing a cup handle out acrylic. Glue and fasteners were prohibited. My goal was to minimize weight and maximize robustness. Aesthetics were considered but took second place to the primary objectives.

Max Queenan

Final product with cup.

Final product.

Easily hangs from lanyard in many configurations.

Holes in handle decrease weight and vertical stiffener allows it to be put in the bottom of a backpack without fear of damage.

Initial concept drawings for cup handle

Initial concept drawings for cup handle. The focus for this design is low weight and mechanical robustness.

Narrowing down design attributes.

First paper prototype

First paper prototype after bending to shape. Note incorrect bottom radius.

First paper prototype. Also note excessively large hoop diameter, which makes the part larger than it needs to be.

New concept for added vertical stiffener, one of the changes after the first prototype. This made manufacture more complex but increased the strength of the product.

Second paper prototype, with vertical stiffener added and minor dimension changed for proper fitment.

Stiffener too short. This was lengthened before the first acrylic part was cut. Handle is also too long which creates a tendency to bow up at the bottom.

Using the paper mockup to select approximate diameter for acrylic bending jig.

Press fit too high, causing crack. Decreased from .010" to .005" for second part. A few bubbles also popped up from too much heat.

Cup Handle