Credits
Shoutout to Jasmine Thind for putting this design sprint together!
Sprint Goals:
Get members familiar with the tools and skills used to design and optimize an aerobody (including constraints + criteria, surface modelling, and CFD simulations)surface modelling tools in SolidWorks, applying these tools to basic shapes (i.e. a canopy)
Get members accustomed to designing relevant components within the Aerobody and critiquing each other’s work
Learning to make your own design decisions along with applying feedback from peers and leads
Working within deadlines, having made progress with each review
Documenting progress using a design log
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Concept Sketches → Design → CFD Simulations
Solidworks CAD Computer Aided Design (Surface Modelling)
Researching Material and Composites Manufacturing Techniques (Thermoforming)
Sprint Introduction:
You For this design sprint, you are tasked with designing a computer mousea solar car “bubble” canopy (the part of the car that surrounds the drivers head). Typically, this is a removable piece of the car that allows the driver easy access to the cockpit.
The canopy you design can serve as inspiration for the canopy that you put on your aerobody for design sprint #3. It is up to you on how complex and/or unique you want to your canopy design this mouse to be! The skills you will gain from this sprint can easily be applied to designing an aerobody, following the similarities between the general shape of the two!
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There are no limitations or restrictions on your design but be sure to make it realistic and human friendly (i.e., it should fulfil its function and be usable)! For example, do not surface model a simple cube as that would probably not work as a mouse and nor will you learn much from it.
You may use the average dimensions of a mouse as a reference:to be!
Some design considerations:
Aerodynamic performance: how aerodynamic is your canopy, and what shape is it taking? Ideally, it shouldn’t be as simple as a cube as that would be an oversimplification of the sprint and not teach you much about surface modelling.
Size: Will your canopy fit around the driver’s head and the car chassis?
Practicality: Does your design make sense? The canopy consists of both a solid composite portion, and a transparent windshield. What do you think is the best use of the canopy area (i.e. how much windshield vs. canopy should you have)?
While these are suggestions, you are encouraged to take these factors into consideration when designing your canopy, as you will be asked to explain your decision making process during the design review.
DIMENSION TYPE | AVERAGE RANGE |
|---|---|
Length (top to bottom)   | 10cm 170cm - 14cm180cm |
Width (left to right)  | 5cm - 7cm65cm - 85cm This width should include the filleted edge on the bottom of the canopy (the edge in contact with the roof of the car) |
Height   | 2.5cm 40- 5cm |
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50cm |
Timeline:
Please feel free to set up independent reviews with leads or other members. You are not limited to the scheduled reviews.
While this sprint will be introduced before the Surface Modelling 101 session, you are welcome to start working on it and learn as you go. There are various surface modelling resources that can be found both on our confluence (linked below) and online.
The purpose of this first sprint is to get you more familiarized with surface modelling tools, and it will not be as “formal” as the next two sprints. The timeline should be taken as a guideline, and you should work at your own pace.
Week 1:
Begin with conceptual design. Decide how you want to solve the design while keeping in mind constraints and criteria. After finalizing your conceptual design, you should advance to some CAD (the exciting part)!
Bring To Review:An in-progress A completed first CAD iteration within SolidWorks, plus any questions/problems you may be having with surface modelling.
Week 2:
By week three you should have more finalized CAD and should begin adding and perfecting more complex features.
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Note: your first iteration should not be your last! We expect you to bring any questions you may have to the design review, however we acknowledge that this is an easier sprint, and should not take as long as the next two.
Week 2:
A completely finished CAD model should be ready, this should be exactly how you want the design to look like in real life. All dimensions and features should be accurate and modelled using proper techniques. You should also perform CFD simulations on your mouse. Although CFD sims are not too big a concern for computer mouses, they are very important for MSXV! By going through a CFD simulation you will learn how we are working on optimizing the shape of the aerobody to improve our coefficient of drag and overall flow separationbe able to justify your design decisions to us, and walk us through your design process.
Bring To Review: Final CAD Design and Completed CFD sim within Solidworks
Additional:
Once you have finished working on your mouse canopy design, start researching about manufacturing methods. For instance, you may want to start looking into thermoforming. If you were to manufacture this mouse, how possibly can you do so using thermoformingHow can we manufacture a canopy for the car, keeping in mind part of it needs to be clear?
Challenge:
If you are up for a challenge attempt Design Sprint 2, where you will be designing your own aerobody!
Design Log:
Keep a design log for all progress! A design log will help organize all content for presentation.
Sample Design Logs:
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Mouse!
https://docs.google.com/presentation/d/10ylmWYR_Er4OoCQ5UJIiymEIGTLgjv72pMDDRAr9HMI/edit?usp=sharing
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Surface Modelling *Highly suggest going through this session as it goes over all the basics you need*https://youtu.be/lnJTfrqYfMU *If you are looking for a tutorial to follow as practice before beginning your own, this video can help*
/wiki/spaces/MFG/pages/1453817927 *For more information on thermoforming*