Design Process Report

MP3 Docking Sound System

Walter Dorwin Teague Sparton Series

Lando Di Girolamo

Original Concept Sketch

The first iteration of the Sparton style dock was an L-shaped design that hides the I-pod away around the back.

The reasons for putting the I-pod around the back was because I didn't want it mounted on-top. It reminded me of Deco Blasters Which I didn't want to imitate

http://www.thedecoblaster.com

CAD Attempt of original Design

This attempt at making the block shape of this design was for scale reference only.
After putting some measurements in, things seemed to become awkwardly proportioned etc. The next stage was to make a sketch model of the design to get a complete understanding of the scale issues

Foam model
After making the foam model is was confirmed that the scale was just way too off and that this shape would not work So I went on to make a second foam model with a slightly different shape

nd 2

Foam Model

This foam model got rid of the L-shape and made for a more compact Docking station, and was already seeming more visually appealing. Then from this I sketched a more developed idea of this basic shape change.

New Concept Sketch

The sketch mimicked the foam model in shape etc As I had already made the foam model I knew the scale. I then went into Solid works to start sorting out the proper model, including manufacturing strategy etc

CAD Model of New Design

The intended manufacturing process for this model was to be injection moulding. The part line I had imagined was not possible with injection moulding as it would of created Enormous amounts of undercuts Severe draft issues too deep of a part to allow ejection I decided to use a different material and a different process.

rd 3

Attempt CAD Model

After reading through speaker forums and wood working site I decided to do with MDF as my material. The main reason is that MDF is the material used for many high end speaker boxes. MDF also it allows for CNC machining as a manufacturing strategy. Which is the process I have chosen for the manufacture of the main body of the dock. However, this design could not comfortably accommodate the I-Pod without resorting to Deco Blaster tactics. A fourth and final model was needed to resolve all issues.

Final Concept Sketches

I had two possible designs to go with on the Final concept, the only differences between them was the strips that wrap around the front.

Concept 1

Concept 2

th/Final 4
The front, top and side panels fits together with Mitre joints to create a box with no lid type scenario. The back panel has a lip that fits inside of a cavity created by the three other panels with a rubber seal to create an air-tight box.

CAD Model

th/Final 4

CAD Model

Final changes to the design include a flipping over of the front panel, to put the curve on the bottom. This makes it sit lighter than the previous design with the flat bottom This box is constructed using 12mm MDF sheets that is CNC machined to fit the tech pack etc. Kerfing cuts are used to achieve the curve in the wood from a solid piece.

An example of Kerfing

th/Final 4
There are now 4 strips that wrap all the way around, including over the speaker section. The Dock is now Exclusive to I-phone 4, this is a styling decision because the I-phone 4 is very in tune with Art Deco styling, as is the dock itself. The I-phone is now mounted at the front, in a recessed well that cradles it.

CAD Model

th/Final 4
To Mount a lot of the tech pack etc, some plastic parts were needed. These would be simple injection moulded parts, some are even available to buy off the shelf

CAD Model

I-Phone Well
Secured with Screws

Infar-Res Lens Cover

Secured with Glue

PCB Support Clip

Secured with Glue

Screw Gussets
Secured with Glue

th/Final 4

CAD Model

Bass Ports
Secured with Screws

PCB Support/Buttons
Secured with Screws

Cloth Frame
Secured with Snap inserts

th/Final 4

CAD Model

The tech pack layout is fairly compact once all the components are placed inside. The tech pack consists of: 2 speakers 4 PCBs of varying size 1 Infar red lens 2 Bass ports
Each of these components needed to be fitted to the dock in some way. The choice of material makes it necessary to use insert-able attachment methods. Some of the components provided fastening holes etc, these were taken advantage of where possible.

th/Final 4
In total there are 40 fastening features in this product 20 small screws 4 large screws 4 PCB supports 4 Gussets with threads 8 Screw inserts

CAD Model

Screw Insert

th/Final 4

CAD Model

These features secure the tech pack to the dock, some use screws and some use snap connections.

th/Final 4

CAD Model

Elevations with all tech components shown

Remote
The remote for the final design, simply references the aesthetics of the dock, as well as the I-Phone 4.

Remote
The remote housing is an injection moulded plastic part, which houses the remote PCB. The moulded ribs hold the PCB in place and line up the LED with the hole in the remote

Remote
Securing the battery inside the battery housing is done with a C-clip/battery housing. The battery housing sits flush with the rest of the housing. With a small lip on the bottom to help pull it out and change the battery.

Computer Generated Render

The final computer generated renders of the Docking station shows the materials and finishes that are planned for the final product. The Materials are mainly Black Painted MDF and Polished Aluminium MDF box Painted black with deep Piano Polish Strips Polished Aluminium Button Cover Polished Aluminium