Applications and Implications / Project Development

1. Checklist

• ✅ Answered what the final project does
• ✅ Researched and described previous related work, including Adrián Torres' Fab Academy train project
• ✅ Identified the sources used for inspiration, technology and documentation
• ✅ Documented what I designed for the final project
• ✅ Listed the materials and components used in the project
• ✅ Created a detailed integrated BOM with exact component values, package types, quantities, sources, unit costs and subtotals
• ✅ Explained where the materials and components came from
• ✅ Estimated the cost of the final project using a Bill of Materials
• ✅ Documented the parts and systems made for the final project
• ✅ Documented the processes used to fabricate and program the project
• ✅ Identified the questions that were answered during project development
• ✅ Explained how the project was evaluated
• ✅ Added quantitative performance results for sensor range, communication latency, stopping time and stopping distance
• ✅ Verified that the final slide and video are documented in Week 20
• ✅ Added buttons to access the final slide, video and Week 20 requirements page
• ✅ Included links to downloadable design and code files
• ✅ Documented the current status of the project as a complete integrated system

2. Nueval Evaluation Mapping

This table maps the Fab Academy project development questions to the sections of this documentation. I organized the page this way so that each evaluation point can be reviewed clearly.

3. Project Overview

My final project is called Fab Train. It is an interactive STEM train kit where a 3D printed train moves on CNC-machined wooden rails, communicates with a smart station through WiFi, controls motor and LED behavior, and sends data to a Blynk dashboard.

The project integrates several Fab Academy skills into one system: 2D and 3D design, CNC machining, 3D printing, electronics design, electronics production, embedded programming, input devices, output devices, networking, interface design, system integration and packaging.

The current version is documented as a completed final project. The train has already been tested on the wooden rail circuit. The project includes the train, wagon, rail system, smart station, electronics, dashboard and final packaging. The station detects the train using a Sharp distance sensor, updates data in Blynk and interacts with the train through WiFi.

4. What Will It Do?

Fab Train is a modular train system designed for STEM learning. The user can assemble different rail configurations, place the train on the track, turn it on and observe how the train moves through the circuit.

The train includes an internal PCB with a XIAO ESP32-C6, motor control, LEDs and battery monitoring. The station includes another XIAO ESP32-C6, a Sharp distance sensor and LEDs. Both systems communicate through WiFi and their states are visualized in Blynk.

When the train reaches the station, the station detects the train using the distance sensor. The station updates the distance value in Blynk, changes LED states and sends a stop command. The train stops until the user presses the Blynk button again to resume movement.

The Blynk dashboard allows the user to view and control the system. It shows motor state, train LED state, station distance, station stop command, battery voltage, battery percentage and motor PWM speed. The motor speed can be adjusted from the dashboard.

5. Who Has Done What Beforehand?

Before developing Fab Train, I reviewed different types of existing projects and products related to educational trains, STEM kits, interactive toys and IoT dashboards. These references helped me understand what already exists and how my project could combine these ideas through digital fabrication.

6. What Sources Will I Use?

The project uses different types of sources: Fab Academy documentation, component datasheets, software documentation, existing educational products and my own design and fabrication files.

7. What Will I Design?

For the final project, I designed the complete Fab Train system instead of buying a finished product. The project includes custom mechanical parts, custom rail geometry, custom electronics, custom station parts and custom packaging.

• Modular wooden rail system with straight pieces, curves and bifurcations.
• 3D printed locomotive body.
• 3D printed wagon.
• 3D printed wheels and axles.
• Train PCB with XIAO ESP32-C6, power regulation, motor control and battery reading.
• Station structure for the sensor and LEDs.
• Station PCB with XIAO ESP32-C6, Sharp distance sensor and LEDs.
• Blynk dashboard with widgets and datastreams for train and station data.
• Packaging design using a box structure and adhesive vinyl artwork.

8. What Materials and Components Will Be Used?

The project uses materials for digital fabrication, electronic components, mechanical assembly components and packaging materials. The following table summarizes the main material groups used in the final project.

9. Where Will They Come From and How Much Will They Cost?

To answer the origin, quantity, technical specification and cost questions clearly, I created a single integrated Bill of Materials. The table includes the exact component values, package type, quantity, source, function, unit cost and subtotal for the complete Fab Train prototype.

The costs are based on real local prices when available. For small electronic components without an individual purchase invoice, I used a reasonable local electronics market estimate. Workshop tools and consumables such as CNC end mills, sandpaper and general equipment are not included because they are not part of the final kit.

The estimated total cost of the complete Fab Train prototype is approximately 126.50 USD. This value includes the individually detailed resistors, LEDs, capacitors, PCB materials, mechanical components and fabrication materials. The final value may vary depending on local suppliers, available Fab Lab inventory, shipping costs and material waste.

10. What Parts and Systems Were Made?

Fab Train is made from several subsystems that were designed, fabricated and integrated into one final product.

11. What Processes Were Used?

The final project integrates additive, subtractive, electronic and digital processes. Each process was connected to a specific part of the system.

12. What Questions Were Answered?

During development, the project answered several technical and design questions related to movement, electronics, sensing, communication and user experience.

13. How Will It Be Evaluated?

The evaluation of Fab Train is based on functionality, integration, reliability and presentation as a finished product.

14. Quantitative Performance Results

To improve the evaluation of the final project, I documented quantitative performance results from the tests performed with the integrated Fab Train system. These tests focused on station detection, communication response, stopping behavior, repeatability and dashboard monitoring.

The system was tested with the train moving on the MDF rail circuit, the station powered from an external 5 V supply, and the train communicating with the Blynk dashboard through WiFi. The values below were obtained from repeated functional tests and observation of the dashboard, station LEDs and train behavior.

These tests showed that the project works as an integrated system, but also revealed important limitations. The first version of the station logic did not stop the train reliably because the train could pass through the detection zone before the command was fully processed. To solve this, I modified the code so that once the station detects the train, the event is stored as a latched stop command. With this correction, even if the train passes the sensor quickly, the stop command remains active and the train stops approximately one second later.

The final behavior is acceptable for this educational prototype: the station detects the train in the 11–14 cm range, the command is transmitted through WiFi and Blynk, and the train stops approximately 5 cm after the detection point. This validates the interaction between input sensing, communication, output control and dashboard monitoring.

15. Blynk Dashboard and Data Flow

The interface was created using Blynk. I used the Blynk panel, widgets and datastreams to visualize and control the train and the station at the same time. The programming was done in the Arduino IDE.

The train and station communicate through WiFi and update their values in the Blynk dashboard. This makes the system easier to understand because the user can see what is happening in both devices from one interface.

16. Presentation Slide and Video Check

As part of the project development requirement, I prepared and verified the final project presentation files: presentation.png and presentation.mp4. These files are used for the final presentation and are documented in the Final Project Requirements page.

The final slide summarizes the project name, student name, Fab Lab, project image, assignments used, main features and a short description. The video shows the conception, construction and operation of Fab Train.

I also checked that these files are visible from the final project presentation documentation and that the file names match the required convention.

17. Final Project Requirements Mapping

The final project integrates the range of Fab Academy units covered during the program. This table explains how each major final project requirement is included in Fab Train.

18. Current Project Status

Fab Train is documented as a completed final project. The rail system, train, wagon, PCBs, station, WiFi communication, Blynk dashboard and packaging are part of the final integrated system.

The user can assemble the rail system according to the desired path, place the train on the rails, turn it on and monitor the system using Blynk. The internal electronics are protected and are not intended to be handled by children during normal use. The interaction is simple: the kit is assembled, the train is powered on, and the dashboard displays the state of the system.

The station currently works with an external 5 V power source connected to the XIAO 5 V pin to power the circuit. A future version could replace this with a rechargeable battery or a dedicated AC/DC power supply with the required voltage regulation. The train uses a 9 V battery, but a future improvement could be to replace it with a rechargeable battery system and include an integrated charging method.

19. Future Improvements

Although the project is complete, there are several possible improvements for future versions:

• Replace the 9 V battery with a rechargeable battery system.
• Design an integrated charging system for the train.
• Improve the power system of the station with a regulated AC/DC adapter or battery option.
• Test long-term battery autonomy during extended demonstrations.
• Add more stations and additional sensors to create more interactions.
• Add more track modules to increase the number of possible rail layouts.
• Improve the robustness of the train for repeated use by children.
• Create guided STEM activities for workshops or classroom use.
• Add more dashboard functions, such as lap counting or event history.
• Improve the packaging to include internal separators for each component.

20. Downloadable Files

The following files are included so the project can be studied, reproduced or modified. The files are organized by code, 3D printed parts, packaging, Gerber files and laser cut designs.

21. Reflection

• This assignment helped me organize the final project as a complete system, not only as separate mechanical, electronic and digital parts.
• I learned that answering the project development questions makes the final project easier to evaluate because each requirement becomes visible.
• Adding a clear reference to Adrián Torres' Fab Academy train project helped me position my work more fairly in relation to previous work and understand how my project differs in scope and educational purpose.
• Preparing an integrated Bill of Materials helped me understand the real cost of the prototype and clearly connect each component with its source and purpose.
• The rail system showed me the importance of designing physical parts with assembly and user interaction in mind.
• The train design required several iterations because the 3D printed parts had to fit the mechanical rail system and the internal electronics.
• Designing custom PCBs helped reduce the amount of loose wiring and made the project closer to a finished product.
• Using WiFi and Blynk made the system easier to understand because both the train and station could be monitored from a dashboard.
• The dashboard is useful not only for control, but also for debugging, because it shows battery, motor, LEDs and sensor values.
• The packaging was important because it changed the project from a prototype into something that looks more like an educational kit.
• I learned that a finished project must consider not only function, but also usability, safety, documentation, cost, assembly and presentation.
• The main technical challenge was integrating all systems together: rails, train, station, sensor, motor, PCBs, WiFi and dashboard.
• A future version should improve the power system by using rechargeable batteries and a safer charging strategy.
• Fab Train has potential as a STEM learning tool because it combines play, fabrication, electronics, programming, IoT and data visualization.