Download - Sparton 600i Design Process
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Design Process Report
MP3 Docking Sound System
Walter Dorwin Teague
Sparton Series
Lando Di Girolamo
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Original Concept Sketch
The first iteration of the Sparton style dock wasan L-shaped design that hides the I-pod away
around the back.
The reasons for putting the I-pod around the
back was because I didn't want it mounted
on-top. It reminded me of Deco Blasters
Which I didn't want to imitate
http://www.thedecoblaster.com
http://www.thedecoblaster.com/http://www.thedecoblaster.com/http://www.thedecoblaster.com/ -
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CAD Attempt of original Design
This attempt at making the block shape of
this design was for scale reference
only.
After putting some measurements in,
things seemed to become awkwardly
proportioned etc.
The next stage was to make a sketch
model of the design to get a completeunderstanding of the scale issues
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Foam model
After making the foam model is was confirmed
that the scale was just way too off and that
this shape would not work
So I went on to make a second foam model
with a slightly different shape
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2nd Foam Model
This foam model got rid of the L-shape and made
for a more compact Docking station, and was
already seeming more visually appealing.
Then from this I sketched a more developed idea
of this basic shape change.
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New Concept Sketch
The sketch mimicked the
foam model in shape
etc
As I had already made the
foam model I knew thescale.
I then went into Solid works
to start sorting out the
proper model, including
manufacturing strategyetc
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CAD Model of New Design
The intended manufacturing process for
this model was to be injection
moulding.
The part line I had imagined was not
possible with injection moulding as
it would of created Enormous amounts of undercuts
Severe draft issues
too deep of a part to allow ejection
I decided to use a different material and
a different process.
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3rd Attempt CAD Model
After reading through speaker forums andwood working site I decided to do with
MDF as my material.
The main reason is that MDF is the
material used for many high end
speaker boxes.
MDF also it allows for CNC machining as amanufacturing strategy. Which is the
process I have chosen for the
manufacture of the main body of the
dock.
However, this design could not comfortably
accommodate the I-Pod withoutresorting to Deco Blaster tactics.
A fourth and final model was needed to
resolve all issues.
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Final Concept Sketches
I had two possible designs to go with on the Final concept, the only differences between
them was the strips that wrap around the front.
Concept 1 Concept 2
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The front, top and side
panels fits together
with Mitre joints to
create a box with no lid
type scenario.
The back panel has a lip
that fits inside of a
cavity created by the
three other panels with
a rubber seal to create
an air-tight box.
4th/Final CAD Model
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4th/Final CAD Model
Final changes to the design include a flipping
over of the front panel, to put the curve on
the bottom.
This makes it sit lighter than the previous
design with the flat bottom
This box is constructed using 12mm MDFsheets that is CNC machined to fit the tech
pack etc.
Kerfing cuts are used to achieve the curve in
the wood from a solid piece.
An example of Kerfing
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4th/Final CAD Model
There are now 4 strips that wrap all
the way around, including over
the speaker section.
The Dock is now Exclusive to
I-phone 4, this is a stylingdecision because the I-phone 4
is very in tune with Art Deco
styling, as is the dock itself.
The I-phone is now mounted at the
front, in a recessed well thatcradles it.
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4th/Final CAD ModelTo Mount a lot of the tech pack etc,
some plastic parts were needed.
These would be simple injection
moulded parts, some are even
available to buy off the shelf
I-Phone WellSecured with Screws
Infar-Res Lens CoverSecured with Glue
PCB Support ClipSecured with Glue
Screw GussetsSecured with Glue
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4th/Final CAD Model
Bass PortsSecured with Screws
PCB
Support/ButtonsSecured with Screws
Cloth FrameSecured with Snap inserts
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4th/Final CAD Model
The tech pack layout is fairly compact once all thecomponents are placed inside.
The tech pack consists of:
2 speakers
4 PCBs of varying size
1 Infar red lens
2 Bass ports
Each of these components needed to be fitted to
the dock in some way.
The choice of material makes it necessary to use
insert-able attachment methods.
Some of the components provided fastening holes
etc, these were taken advantage of where
possible.
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4th/Final CAD Model
In total there are 40
fastening features in
this product
20 small screws
4 large screws
4 PCB supports 4 Gussets with threads
8 Screw inserts
Screw Insert
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4th/Final CAD Model
These features secure the tech pack to the dock, some use screws and some use
snap connections.
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4th/Final CAD Model
Elevations with all
tech components
shown
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Remote
The remote for the final design, simply
references the aesthetics of the dock,
as well as the I-Phone 4.
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Remote
The remote housing is an injection
moulded plastic part, which
houses the remote PCB.
The moulded ribs hold the PCB in
place and line up the LED withthe hole in the remote
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Remote
Securing the battery inside the batteryhousing is done with a C-clip/battery
housing.
The battery housing sits flush with the rest of
the housing. With a small lip on the
bottom to help pull it out and change thebattery.
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Computer Generated Render
The final computer generated renders of the Docking station shows the materialsand finishes that are planned for the final product.
The Materials are mainly Black Painted MDF and Polished Aluminium
MDF box Painted black with deep Piano Polish
Strips Polished Aluminium
Button Cover Polished Aluminium
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