MA Project: A Mechanical Interactive Prototype

Project Overview

This project involved the design and development of a mechanically driven interactive prototype as part of my MA Product Design final project. The objective was to translate complex CAD assemblies into a functional physical system incorporating gears, shafts, and moving components, with a strong emphasis on buildability, alignment, and mechanical reliability.

Final product placed during the exhibition at Sheffield Hallam University.

Engineering Brief

Design a functional mechanical system with multiple interacting components.
Convert CAD assemblies into a working physical prototype.
Ensure correct gear meshing, alignment, and motion transfer.
Manufacture parts using FDM 3D printing and manual assembly.
Allow repeatable and controlled motion through user interaction.

Mechanical Design & CAD Development

The system was designed using AutoCAD, with careful consideration given to gear layouts, shaft positioning, and spatial constraints. Assemblies were modelled to evaluate motion paths and ensure compatibility between components prior to installation.

Prototyping & Iteration

Initial prototypes were produced using FDM 3D printing and manually assembled. Early testing revealed issues related to alignment, friction, and gear engagement. These findings informed subsequent design revisions, resulting in improved motion smoothness and overall system reliability.

3D Printed & Laser Cut Parts

Me assembling the laser cut parts.

Me soldering the LED lights for the background of the model.

Outcome & Learning

The final prototype successfully demonstrated controlled mechanical motion and validated the CAD-to-prototype workflow. The project strengthened my understanding of mechanical tolerances, assembly sequencing, and the importance of iterative prototyping when developing functional products.

Model before finish work.

Key Skills Demonstrated

Mechanical system design and motion transfer.
CAD assemblies and layout planning.
Design for additive manufacture.
Hands-on prototyping and testing.