Pastoral Kit Design Brief Kunal, Jayce, and Kailash

http://easel.inventables.com/projects/jhndplBgVfCqzUltgV4cYg

Problem:

The challenge is to create an assembly kit that meets design and manufacturing constraints while
remains fun and easy to build. We target young children and grandparents. Grandparents are
looking for a way to connect and bond with young grandchildren.

Ideas:

- Truck

- Sailboat
- Limo (1)

- Connect 4

- Chess
Research:

Designing a derby car

- Sketch on a piece of paper the size of your block of wood.
-The fastest cars look like a wedge, with the front narrow.
-Get supplies of wheels and nails from a hardware store
-Decide how to cut the car
-Trace the design onto a piece of wood
-Sand the car
-Paint the car by thin coats
- Put on wheels
-weigh the car
WikiHow. (2017, June 26). How to Make a Pinewood Derby Racing Car. Retrieved September
26, 2017, from http://www.wikihow.com/Make-a-Pinewood-Derby-Racing-Car

Building a car using CNC

-Layout your design in any software that has capability of importing into a CNC router
-Make sure parameters are right
-Create two side and one inner portion to connect your wheels
-Set it to a shallow, outline cut when cutting your design
-Using a scrollsaw or a hand saw, cut the tabs of to remove your piece from the wood
-Sand the tabs off to have a smooth layout
-Glue them together and use a bearing press to secure them
-CNC cut your wheels and use a screw, bolt and a rubber washer to create your wheels
-You a drill dress to create an axle hole
-Assemble everything together and sand and paint if needed

D. (2016, January 15). Retrieved September 26, 2017, from

https://www.youtube.com/watch?v=PDYCpWLUhEo

Wooden Car Puzzle Kit

- DIY: The Wooden Puzzle is a non-finished product, and need you to assemble it by
yourself
- SAFE AND EXCELLENT: High-quality natural wood, safe and nontoxic, no glue or
tools required
- EDUCATIONAL TOY: culture kids’ abilities such as creativity, concentration,
confidence and hand-eye coordination
 - FAMILY FUN: Perfect family game, especially fit adults and children to play it perfect
together
- PRETTY DECORATION: Perfect item to decorate your rooms, tables and showcases,
etc.

3D Wooden Puzzle Building Kit Pickup Truck Car Model Wood Best Gift For Kids 23-pcs
(Pickup Truck): Toys & Games. (n.d.). Retrieved September 27, 2017, from
https://www.amazon.com/Wooden-Puzzle-Building-Pickup-23-
pcs/dp/B0719XBPS6/ref=sr_1_2?ie=UTF8&qid=1506516139&sr=8-
2&keywords=wooden%2Bcar%2Bkits

Criterias:
❏ Enjoyability
❏ Ease of assembly
❏ Manufacturing Time
❏ Packaging
Constraints:
❏ Must be made on the CNC Router
❏ The stock size is limited to 11 ½” by 7 ½” by .190”
❏ Must limit excessive sanding.
More Ideas:
Refined Limo to match constraints
Costs:
Plywood- $1.16
Glue- $3.00
Paint kit- $1.21
Sandpaper- $0.31

Total- $6.84

Proposal

The challenge is to create a pastoral kit that is fun and exciting to build. Grandparents are
looking for a way to bond with the young generation. We believe this project is that connection.
It is an easy to build kit that is fun for the young and the old. We have done research on how our
kit is being fabricated as well as other kits that are available to build. We looked at other kits by
other kids toy manufacturers such as Hasbro. Mattel, and Fisher Price to find inspiration and the
capabilities of our consumer. We were able to identify that the toy must be simple as well as
interesting in order to capture the eyes of the consumers.

In order to create a well structure and ideal toy, we looked at the basics of CNC routing
to constrain our manufacturing process. We looked at how other toy cars are made. We used
AutoCAD to design our parts. We used Inkscape to convert the file into an .svg file format. We
then used Easel to communicate with the machine (WikiHow, 2017). This process creates
repeatability in the product.

In our kit, we will include paint, as well as superglue for an adhesive. Sandpaper is
included to further refine any sharp lines. The theme of the kit is a limo. It is made of similar
segments glued together with super glue. There are 7 main body pieces, 2 side pieces, and 4
wheels. Everything glues together in predefined spots. The design encompasses the main features
of a limo, 4 wheels and a long body (D, 2016). We plan to design a product the simple and
intuitive to assemble. We will test the looks by using a 10 person survey to rate the looks from 1
to 10. If a high schooler can put it together in less than 30 min, it is easy to assemble.

The cost for materials would include 1 peice of 150 grit sandpaper, 1 tube of superglue, 1
painting kit, as well as raw materials for each 7.5in x 11in sheet of wood. We plan to finish
testing the prototype in one week. We will then create a graphic to market the product. We will
sell this product for $10 and it will cost us 6.84 to produce. We will sell on Amazon. After four
months, we hope to have over 200 sales.

Sources
______________________________________________________________________________
WikiHow. (2017, June 26). How to Make a Pinewood Derby Racing Car. Retrieved September
26, 2017, from http://www.wikihow.com/Make-a-Pinewood-Derby-Racing-Car

D. (2016, January 15). Retrieved September 26, 2017, from

https://www.youtube.com/watch?v=PDYCpWLUhEo

3D Wooden Puzzle. Retrieved September 27, 2017, from https://www.amazon.com/Wooden-

Puzzle-Building-Pickup-23-
pcs/dp/B0719XBPS6/ref=sr_1_2?ie=UTF8&qid=1506516139&sr=8-
2&keywords=wooden%2Bcar%2Bkits

Instructions:
1. Glue Pieces C,D,E,F,G,H,I together
2. Glue side A on one side of C-I block
3. Glue side B on other side of C-I block
4. Glue wheels on
5. Sand block to wanted smoothness
6. Paint using provided colors.
 Create Create a
a complet
prototyp ed
e on the product
5 DAYS 5 DAYS

Test and
iterate the
prototype
based on

Prototype #1
Our first prototype met the design specifications. There were no manufacturing errors.
All the parts came out of the mill and were pre-sanded. They then were glued together using
super glue. A second round of sanding smooths out all the bumps and grooves. The second round
uses 120 grit sandpaper. Then, using 220 grit sandpaper, it was finished to a smooth surface.
Then a finish was applied. In this case, we used superglue to provide a finish and covering to the
product.
The main body glued together well. The glue up was very smooth and easy. However,
one of the main body pieces was left out because the body was becoming too thick. Another
issue was the thickness of the wheels. They were quite thin. The sanding turned out well. We got
a super smooth finish on the car. The super glue finish created a layer of protection over the car,
however it did not look as good as it could.
For the next design, we will remove one of the main body pieces completely. We will
also switch two main body pieces to side pieces and put in thicker wheels. We will use the same
sanding technique. We will be using paint or a different finish(spray finish).
Lessons Learned:
We found that the first prototype was quite bland in its construction and was not very fun to play
with. It was also very easy to assemble and did not provide the challenge or skill level for
construction. The car had wheels but the wheels did not spin, so the toy was not useful.

Prototype #2
We have updated our design to a more intricate and appealing look. The outside panels of
the car now have windows cut in them and designs for doors. A hole has been added where the
wheels are to make room for an axle, which will be a toothpick. During the assembly process the
toothpicks need to be sanded to fit in the axle holes and the ends need to be cut and sanded so
they’re not sharp. The wheels have been made larger with a hole in the middle for the axle. The
car can roll now and be played with.
The design can be colored in a variety of ways from sharpie to paint or with a finish.
There were no malfunctions while cutting this design and the assembly process went well. The
sanding process is the same but more needs to be done because of the added window cuts, they
needed to be sanded extra to be smooth. The assembly process is a little bit more challenging
and time intensive and creates more time for a bond of the people building it.
Alterations:
From prototype 1-
● Removed one body piece
● Developed side pieces
● Thicker wheels
● Different finish
● Put a design on the sides of the car
● Holes in wheels for axle
● Axle, to make it roll
● Toothpick as axle
______________________________________________________________________________

Evaluation: (Scored on a scale from 0 - 10 by evaluators)

Design- 9/10

Flexibility- 10/10

Intuitive- 10/10

Procedure- 9/10

Features- 8/10

Upon evaluation we were told to work making the window more flush within the car. We were
also advised to make changes in how we present our procedures. Evaluators were impressed by
the features but desired to see it working due to the wheels not working the moment we
presented our kit.
__________________________________________________________________________
Final Report:
Our pastoral kit design is a toy car in the shape of limousine. We believe that this design is the
best design to create an assembly kit that is easy to assemble and fun for all ages. The limo is
shipped in a single piece of plywood and all the parts are broken down and put together by the
end consumer. The design also satisfies our criteria. It is enjoyable to both build and play with
and is easy to assemble, while still providing a challenge. The design also meets manufacturing
criteria by keeping machining time below 30 min. It is also packaged very nicely in a sleek form
factor. We tested these criteria in our evaluation. Our 2nd prototype was displayed at the
evaluation. We found that our kit was conceptually very feasible. However, there was a little bit
of work left to do so that wheels would rotate and the rest of the car flowed smoothly. To further
improve this car, we would use advanced CNC milling techniques to create contours from left to
right, with bigger pieces towards the center. This would create a more interesting piece when
assembled. We would also try to remove the use of an adhesive from our project to make it more
kid-safe. I hope that the kit will be built by kids with the help of their grandparents. The car will
then last for many years as the child continues to play with the kit, hopefully cherishing many
memories.