Assignment :

Propose a final project masterpiece that integrates the range of units covered, answering:
• What will it do?
• Who's done what beforehand?
• What will you design?
• What materials and components will be used?
• Where will come from?
• How much will they cost?
• What parts and systems will be made?
• What processes will be used?
• What questions need to be answered?
• How will it be evaluated?
Individual assignment:
• Your project should incorporate 2D and 3D design,
• additive and subtractive fabrication processes,
• electronics design and production,
• microcontroller interfacing and programming,
• system integration and packaging
• Where possible, you should make rather than buy the parts of your project
• Projects can be separate or joint, but need to show individual mastery of the skills, and be independently operable

1. What will it do?

My final project is a dust sensor which will measure the amount of airborne dust particulate matter in my Project Lab (which is a carpentry workshop that I manage) and in-turn display the reading onto the LCD display screen. It will display PM10 and PM2.5 readings.

PM10 is particulate matter 10 micrometers or less in diameter. PM10 is generally described inhalable coarse particles.

PM2.5 is particulate matter 2.5 micrometers or less in diameter. PM2.5 is generally described as fine particles.

In addition, if the reading of PM2.5 exceed a pre-defined limit, the buzzer of the dust sensor will sound.

2. Who's done what beforehand?

1) M 2.5 Sensor running from an Arduino Uno Rev 3 board :
http://fab.cba.mit.edu/classes/863.16/section.EECS/people/Jain/articles/2016-12/final-project-planning.html

2) Arduino Tutorial : A dust sensor running from an Arduino Fio board :
http://arduinodev.woofex.net/2012/12/01/standalone-sharp-dust-sensor/

3) A PM 2.5 Sensor connected to a Particle Photon :
https://www.hackster.io/edwios/air-quality-monitor-3f422f

3. What will you design?

I will design :
1) The PCB or electronic board to take in reading form the dust sensor module and output to a LCD display module and a buzzer (if unhealthy limit is reach).
2) A 3D-print support frame to hold the electronics comonenets together. 3D Print is a form of additive manufacturing which give me more flexibility in my design, to design to the shape and size I want.
3) A 3mm thick wooden/acrylic plastic enclosure box. Using laser cutting, a form of subtractive manufacturing.

First impression in 3D of my final project without the 3D print support frame (not design yet yet)

4. What materials and components will be used?
5. How much will they cost?

Note :

Digital fabrication tools/machine require :

Proposed Input Device : PM2.5 Air Quality Sensor

Proposed Output Device : LCD display, Buzzer

6. Where will come from?

Most of the electronic components can be found in the SP Fab Lab like buzzer, LCD display module, copper claded FR1 material for PCB milling. PLA filament for 3D printing is provided by the Fab Lab. Estimated PLA material require to be less than 8m.

For the specialise PM2.5 dust sensor module and other electronic components which are not in the Fab Lab inventory, will need to be purchased from online shop.

For the 3mm thick plywood or acrylic sheet used to fabricate the enclosure box, it will be purchase from local art and craft shop.

7. What parts and systems will be made?

Electronic board - made
Enclosure box - made
Support frame to hold the Dust Sensor, LCD display module, etc - made

8. What processes will be used?

2D/3D Design - Autodesk Fusion 360 software
PCB Designing - Autodesk EAGLE software
PCB fabrication process - StepCraft 420 PCB milling machine
Stuffing of components - Soldering station, soldering wire and soldering tool
Additive manufacturing process - 3D Printer
Subtractive manufacturing process - Laser cutter
Testing and troubleshooting of electronics : - Digital multimeter

9. What questions need to be answered?

1. How can I fit the various electronic components inside the enclosure?
2. How the various electronic components going to be connected together?
3. Is there a way to have a neat cable run inside the enclosure? A cable mamagement tube/tray?
4. Will the dust sensor work accurately as advertised?
5. Will the enclosure box be stable and not filmsy or easily broken?
6. Where will the source of power coming from?
7. How long does the dust sensor last in normal office environment? or in a dusty environment? Dust is inevitably produced in the Project Lab. If the workshop environment is very dusty, how long will the dust sensor last? I would need to be able to remove the dust sensor for cleaning, or replace the dust sensor if needed.

9. How will it be evaluated?

1) Successfully design and fabricate the enclosure box. Enclosure box should not be shaky and flimsy
2) Successfully design and fabricate the support frame
3) Support frame is able to securely hold the various componenets together
4) Successfully design and fabricate the electronic board (PCB milling, soldering the components)
5) The fabricated electronic board is able to integrate with the LCD display module, the buzzer, the 5V power jack and power switch. Connection and programming
6) LCD Display module is able to display PM2.5/ PM10 reading
7) Buzzer is able to sound if a pre-defined unhealthy PM2.5/PM10 limit is reach or exceeded