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The model is displayed with a small piece of flown material from the capsule. As the section of material is quite delicate and very small, I decided to design an enclosed holder for it, that would also include a magnifier that would enhance the view if it.
The model is displayed with a small piece of flown material from the capsule. As the section of material is quite delicate and very small, I decided to design an enclosed holder for it, that would also include a magnifier that would enhance the view if it.
The magnifier chosen was a jewellers loupe
The magnifier chosen was a jewellers loupe
The holder was designed around the loupe and drawn up in Fusion 360
The holder was designed around the loupe and drawn up in Fusion 360
The profile of the loupe was traced, the trace was scanned and imported into Fusion as an aid to drawing up the correct shape to accommodate it.
The profile of the loupe was traced, the trace was scanned and imported into Fusion as an aid to drawing up the correct shape to accommodate it.
The finished design
The finished design
The holder was then 3d printed by Shapeways. The loupe was stripped of its cover and bolted into place in the holder.
The holder was then 3d printed by Shapeways. The loupe was stripped of its cover and bolted into place in the holder.
The section of material is triangular shaped, so it required something to position it in the holder. A sketch was made and from this a drawing was created using solid edge. This drawing was used to create a cutting template.
The section of material is triangular shaped, so it required something to position it in the holder. A sketch was made and from this a drawing was created using solid edge. This drawing was used to create a cutting template.
The Cameo 4 cutter was used to cut sections of black card.
The Cameo 4 cutter was used to cut sections of black card.
Sections of card “stacked” into the holder to create a pocket to hold the material in place. This was then topped off with a wafer-thin piece of microscope cover glass to protect the section of material.
Sections of card “stacked” into the holder to create a pocket to hold the material in place. This was then topped off with a wafer-thin piece of microscope cover glass to protect the section of material.
The material was inserted and the assembly built up. It was then I noticed a couple of big problems with the cunning plan. Firstly, the magnifier and the cover glass were highly reflective, and it was nearly like looking into a mirror. Secondly I had created a dark “pit” with the use of a black holder and black card. This meant that the section of material was not visible at all.
The material was inserted and the assembly built up. It was then I noticed a couple of big problems with the cunning plan. Firstly, the magnifier and the cover glass were highly reflective, and it was nearly like looking into a mirror. Secondly I had created a dark “pit” with the use of a black holder and black card. This meant that the section of material was not visible at all.
The solution was to illuminate the area with a very small LED light
The solution was to illuminate the area with a very small LED light
In parallel with the holder for the material a design for the base was made. The fairing the shrouds the engine bells has a very distinctive profile, so I decided to trace the kit part, then enlarge it and use it to create a template. This would then be used to have a section of glossy acrylic cut.
In parallel with the holder for the material a design for the base was made. The fairing the shrouds the engine bells has a very distinctive profile, so I decided to trace the kit part, then enlarge it and use it to create a template. This would then be used to have a section of glossy acrylic cut.
Fusion 360 was used to “mock up” the assembled display to visualise the finished article. The emblem to the right of the rocket is from the Mercury program. After an online search a nice pin badge of the emblem was found.
Fusion 360 was used to “mock up” the assembled display to visualise the finished article. The emblem to the right of the rocket is from the Mercury program. After an online search a nice pin badge of the emblem was found.
The acrylic base was ordered from 12mm thick material and received. This happened at the same time that I realised I needed to light up the loupe holder. Lighting up the holder would entail hiding away a power supply and incorporating a switch into the base. It turned out to be impractical to create a void in the 12mm thick acrylic so a change of design was needed. This was done by sourcing a wooden oval base that could have a recess created to hold the battery and wiring.
The acrylic base was ordered from 12mm thick material and received. This happened at the same time that I realised I needed to light up the loupe holder. Lighting up the holder would entail hiding away a power supply and incorporating a switch into the base. It turned out to be impractical to create a void in the 12mm thick acrylic so a change of design was needed. This was done by sourcing a wooden oval base that could have a recess created to hold the battery and wiring.
A thinner piece of acrylic was ordered that would sit on the oval wooden base. The thin acrylic would hold the switch, and the images below shows the acrylic having the mounting holes drilled, and the switch installed.
A thinner piece of acrylic was ordered that would sit on the oval wooden base. The thin acrylic would hold the switch, and the images below shows the acrylic having the mounting holes drilled, and the switch installed.
The underside of the base has threaded brass inserts and angle brackets installed. Epoxy glue was poured into the corners to hold everything in place. The four inserts at the corners will be used for a baseplate. The extra two inserts will be used for a bracket to hold the LED on/off switch into place
The underside of the base has threaded brass inserts and angle brackets installed. Epoxy glue was poured into the corners to hold everything in place. The four inserts at the corners will be used for a baseplate. The extra two inserts will be used for a bracket to hold the LED on/off switch into place
The battery, LED and wiring that will live in the base. Here it is shown mocked up to test it. The final assembly will not have the green connector block.
The battery, LED and wiring that will live in the base. Here it is shown mocked up to test it. The final assembly will not have the green connector block.
The nearly finished base, still with protective coverings on
The nearly finished base, still with protective coverings on
The rocket will be supported by two glossy acrylic rods that will screw into place, and at the top they will have two small brass rods that will engage into the rocket. Image below is the design drawing for the rods and blanks ready for machining that have had a protective covering applied. This job will be completed at work where I have access to a lathe
The rocket will be supported by two glossy acrylic rods that will screw into place, and at the top they will have two small brass rods that will engage into the rocket. Image below is the design drawing for the rods and blanks ready for machining that have had a protective covering applied. This job will be completed at work where I have access to a lathe
The rods were machined at work and the threads tapped in the larger diameter to 6mm
The rods were machined at work and the threads tapped in the larger diameter to 6mm
The base shown built up. At this stage the small switch seen between the two posts is just a push fit into the acrylic sheet and a way of fixing it into place was needed. I had considered just gluing the switch in place but not really a good option
The base shown built up. At this stage the small switch seen between the two posts is just a push fit into the acrylic sheet and a way of fixing it into place was needed. I had considered just gluing the switch in place but not really a good option
The switch securing bracket was knocked up from some scrap pieces of styrene. The outer two screws fix the bracket to the base, the middle screw is threaded into the bracket and is tightened up to the switch and holds it in place. All that remains to be done is to cut a piece of styrene to cover it all.
The switch securing bracket was knocked up from some scrap pieces of styrene. The outer two screws fix the bracket to the base, the middle screw is threaded into the bracket and is tightened up to the switch and holds it in place. All that remains to be done is to cut a piece of styrene to cover it all.
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