System Integration

Have you answered these questions?

Implemented methods of packaging? ✅

Designed your final project to look like a finished product? ✅

Documented system integration of your final project? ✅

Linked to your system integration documentation from your final project page? ✅

Individual Assignment:

Design and document the system integration for your final project

The objective of this assignment, aside from having fun, is to: Develop a graphical interface that interacts with an electronic board (XIAO ESP32C3). In this case, I will create two examples—one with LEDs and another with a servomotor—using serial communication between the PC and the hardware. This task combines software and electronics.This week, I faced some challenges while integrating my project, as the system and mechanism were meant to be placed inside the whale I’m designing. It took me longer than expected because I had to carefully consider which mechanism to use and determine the necessary components to ensure the system fits and works properly inside the object, according to my concept, and so that it looks like a finished piece. Below, I will show the process I’ve been working on.

This week is entirely focused on the final project. Below is the link to go directly to the final project.

1. System Design and Planning

1.1. Designing the concept for the final object.

In week 2, I worked on the modeling by exploring Blender software. Having the initial idea, I started from the concept of designing a whale that moves harmoniously and lights up, all triggered by the sound of a baby crying. With those ideas clearly defined, I began thinking about the mechanism and the components I would use.

1.2. Model the object in 3D using CAD software (Rhinoceros).

For this, I tried using Blender to do part of the modeling, but it became too complicated, so I decided to use Rhinoceros instead.

Did I face any challenges?

Yes, I did. I had to carefully think about how to create the curves, since the shape of the whale is entirely curved, and my goal was to make it as accurate as possible.

Modeling was difficult because I first had to figure out how to build the shapes before actually starting.

In the end, I was able to do it, and I really liked the result. The final shape of the whale met my expectations.

1.3. Definition of the electronic and mechanical components I want to integrate, such as motors, sensors, and a microcontroller.

It took me quite some time to figure out the shape of some small, bone-like parts that could connect with one another. I asked for support from a fellow Fab Academy student, Armando, who is a mechanical engineer.

With his experience, he suggested adding an eccentric point. I didn’t know what that was at first, but he explained that it’s an additional point in the mechanical part of the piece that enables indirect movement or connection.

That point ended up being essential to connect the entire internal spine of the whale. In the end, the simple solution I had in mind evolved into something much more functional and interesting.

To do this, I created a 2D model to better understand how it would work. In the model, you can see a shaft along with the eccentric point that simulates the movement.

I had some difficulties when it came to figuring out how to integrate the electronic system into the whale design.

In addition to the challenges of modeling, one of the most complex parts was planning how to embed the electronic components inside the whale, especially since I also had to consider the movement mechanism.

In the end, I designed a few simple parts. One of them acts like a column with an off-center (eccentric) point. This eccentric point connects to the tail section of the whale.

In the video, you can see how those axes would work. In the end, a very simple solution allowed me to minimize the use of servomotors: instead of the two I initially planned to use, I ended up using only one thanks to a simpler and more efficient system.

Another important aspect, aside from the mechanism, was selecting the right electronic components to ensure the crib mobile works optimally based on my concept.

The components I'm using are:

A NeoPixel, which will display randomly changing colors.

1 SG90 servo motor, which will operate within a rotation angle of 5 to 8 degrees.

KY-038 sound sensor, which will be triggered by the baby’s cry.

Xiao ESP32-C3 microcontroller.

1.4. Placement of each component inside the whale to ensure everything fits correctly.

This is the sketch showing how the components will be arranged inside the whale. They are all connected to a direct power source through a 2-meter USB cable.

Here you can visualize the 3D object, which shows how it will look in the end. The other object represents half of the design, created in this way to make assembly easier. This structure also simplifies the installation of the electronic components.

The device's structure is divided into two symmetrical halves. In the central section, which is the widest, the integration system is located. On the right side, the printed circuit board (PCB) is positioned, while on the left side are the servomotor and sensor. In the central area, the Neopixel strip is placed, connected to the mechanism for visual effects.

2. Printing 3D

2.1. Design the model in 3D.

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2.2. Fabrication of the model using 3D printing.

3. Molding and Casting

3.1. 3D printed mold

3.2. Resin casting

3.3. Place the electronic components inside the mold before performing the final resin casting.

3.4. Integration testing to verify that all components work correctly inside the mold.

4. Results

Reflections

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Access to files

led-arduinoIDE

fabcloud/fabacademy/2025/labs/lima/students/evelyn-cuadrado