Under requirements of my degree, I have to make at least one full visual model showcasing the main design features. To go along side this, I am also building a working model with a Nikon compact camera embedded with-in it, as well as an exploded model showcasing some of the more complex components of the design.
To achieve the design using the equipment available to me, a unique construction needed to be created. Above is a render of all the internal parts necessary to create the two main models. The 3D models were made in Solidworks working from the footprint of the camera and adding in features on by one, cutting them out of a honeycomb profile added for strength. The models are difficult to explain, as features were added over a couple of days resulting in CAD files full of details which I knew were there for a reason, but I couldn't quite explain. To help, I've presented a step by step construction below:
Visual Model
Below we can see the parts for the visual model which were manufactured externally in London by Digits2Widgets. They are Nylon SLS 3D printer parts.
The construction is split into two halves to aid construction and strength. Using a unibody and body cap would not be strong enough when manufactured via SLS. Key parts such as the dials drop in from the outside and are locked into the body with retainer rings:
Below we can see one of the trickier components, the slide mechanism. This will attach to the aluminium exterior. This parts is not accurate to how the design would be in reality, as the slide mechanism would really rely on how the aluminium parts is made. Therefore, every effort has been made to make it as thin and unobtrusive to the aesthetics of the design as possible. Location points for magnets should also help the slide stay open and closed:
With the second half attatched to the body, we can see how the slide mechanism is kept in place while a location point has been added in the form of a slot in order to attach the lens housing. Around this there is a stepped diameter which will allow for a disc to be inserted which will spin 100 degrees with the aluminium lens surround:
Here we can see the lens unit added via the slot seen above.
Now finally we can see the aluminium parts added snugly to the unit:
Working Model
The construction for the working model has different requirements. The most important consideration is how to fit the Nikon compact camera within the body in exactly the correct position. Below you can see the bottom half of the body with a void for the camera to drop into:
Below we can see the camera mounted into the body. To provide access to the control, stepped holes are provided into which pass through aluminium buttons are located:
Here we can see the buttons located exactly in line with the buttons on the camera. They have been trimmed to fit exactly, resulting in the two step feeling of the buttons being felt when pressing the aluminium ones. Holes will be drilled in the exterior aluminium shell to accommodate them:
With the unit closed it is neat and compact. The entire top half can be removed to get access to the camera. This is achieved with magnets and loose interference fits within the aluminium exterior:
Finally the lens unit is added, dropping into the hole in the SLS body. The Nikon lens protrudes into the hole when switched on:
