Applications and Implications

This week is individual work only where I will propose a final project masterpiece that integrates the range of units covered during this cycle. This will incorporate:

• 2D and 3D design
• Additive and subtractive fabrication processes
• Electronics design and production
• Embedded microcontroller interfacing and programming
• System integration and packaging.

Learning outcomes

• Define the scope of a project
• Develop a project plan

Checklist

What will it do?:

• What will it do?:

The cardboard kayak is a radio controlled (RC) model watercraft that simulates a real-world application of a kayak that a person would take out on the water. Since this is a 1/4 scale model of the actual kayak, it will need a means of propulsion other than a paddle; it will be propelled by a brushless DC motor (BLDC) spinning a propeller. It senses water temperature and sends a signal to the operator for display as well as an alarm for unsafe water temperatures for a human to survive if the kayak capsizes. It will have a location/distress beacon onboard to show the operator where it is and flash S-O-S if unsafe water conditions exist. For navigational control, it will have a rudder system to control the direction of travel.

Who has done what beforehand?:

• Who has done what beforehand?:

Although others have made a boat in Fab Academy, I am not aware of anybody making a cardboard boat other than dswaim, the author I am following, who posted this instructable

What will you design?:

• What will you design?:

I will redesign the cardboard boat from dswaim as a 1/4 scale version and design a 3D model of the same. Further, I will design an outrigger system to stabalize the watercraft and a propulsion system to propel it with wind power. The electronics to detect temperature and a wearable to provide output to the operator will be designed as well as control of the location and distress signal electronics. A deck ornament will be designed and produced for aesthetics.

What materials and components will be used?:

• What materials and components will be used?:

• cardboard

• tape
• epoxy glue
• 3D filament
• polyester film
• BLDC
• propeller and fasteners
• electronic speed control (ESC)
• radio transceiver
• radio controller
• LiPo Batteries
• servos
• location/distress beacon
• OLED display
• microcontrollers
• discrete smd components
• connectors
• fiberglass rods
• epoxy resin
• OOMOO 25
• Smooth-Cast 305

Where will they come from?:

• Where will they come from?:

• cardboard - recovered from great flood of 2017

• Fab Lab consumables: tape, epoxy glue, fiberglass rods
• Ordered through Amazon: 3D filament, polyester film, BLDC, propeller and fasteners, electronic speed control (ESC), radio transceiver, radio controller, LiPo Batteries, servos, location/distress beacon, OLED display, epoxy resin, connectors
• Ordered through DigiKey: discrete smd components, microcontrollers
• Ordered through Smooth-On: OOMOO 25, Smooth-Cast 305

How much will they cost?:

• How much will they cost?:

• cardboard - recovered from the GOCAT Fab Lab in West Plains, Missouri after the great flood of 2017: priceless

Fab Lab consumables:

• tape - no cost
• epoxy glue - no cost
• fiberglass rods - no cost

Ordered through Amazon:

• 3D filament - $37 per gram
• polyester film - $23 per roll
• propulsion system (BLDC, propeller and fasteners, electronic speed control (ESC), servos) - $23
• LiPo Batteries - $51
• location/distress beacon - $45
• OLED display - $4
• epoxy resin - $60 per gallon
• connectors - $1 per pair

Ordered through eBay:

• radio communications (radio transceiver, radio controller) - $62.90

Ordered through DigiKey:

• discrete smd components - consumables
• microcontrollers - consumables

Ordered through Smooth-On:

• OOMOO 25 - $32
• Smooth-Cast 305 - $33

What parts and systems will be made?:

• What parts and systems will be made?:

• Internal cardboard form of the kayak hull made by laser cutting cardboard using the redesigned files from dswaim

• Cardboard kayak skinning system designed in Adobe Illustrator and SketchUp. Cut using SignMaster application to send to the vinyl cutter to cut the polyester covering material.
• Temperature sensor system: Seeed Studio XIAO ESP32-C3 reading a LM75 circuit and transmitting data wirelessly
• LED location/distress signal control system. Seeed Studio XIAO ESP32-C3 controlling 12V power to LED.
• Piloting system consisting of cockpit electronics compartment and attached outrigger pontoons.
• Propulsion subsystem consisting of superstructure to house the BLDC and propeller as well as the vertical stabilize and rudder.

What processes will be used?:

• What processes will be used?:

Computer-aided design will be used to 2D design the cardboard form of the kayak and 3D design of the molding (substractive) and casting (additive) production of the deck ornanment, computer-controlled cutting will be used to laser cut the cardboard and vinyl cut the covering material, electronics design and production (substractive) will be used for the temperature sensing and displaying as well as the control circuit for the location/distress beacon; embedded microcontroller interfacing and programming will be used for these circuits, 3D printing (additive) will be used for the propulsion system and the rudder system. The assembly and integration of the subsystems will result in a radio controlled air-propelled waterborne kayak that senses temperature and informs the operator.

What questions need to be answered?:

• What questions need to be answered?:

Is a pontoon sytem required or will the vertical stabilizer be sufficient for stability? Can I finish this project before the end of this cycle?

How will it be evaluated?:

• How will it be evaluated?:

• Does it float without leakage?

• Does it move on the surface of the water?
• Does it provide water temperature indication?
• Does it provide visual location with a beacon?
• Does it sense dangerous water temperature?