Overall though, this project provided me with extensive insights into project management and the prototyping process, encompassing manufacturing skills, the practical application of fits and tolerances, and communication to ensure subsystems interface properly. These experiences also highlighted the importance of resilience and the ability to swiftly adapt strategies in response to unexpected obstacles throughout a project.
HydroPod is a purely mechanical portable shower prototype designed for convenient personal cleaning during car camping trips or after a beach day. While many outdoors enthusiasts don’t mind getting a bit dirty, our team discovered a market for those who prefer to stay clean while camping or need a quick rinse after the beach. As a result, the foundation for our product was born. Our goal was to create a mechanical system that provides an efficient clean while remaining durable, portable, and easy to use. This project originated in one of my classes at Boston University (ME692: Advanced Product Design), where we were challenged to take a product from ideation to a manufacturable prototype. Our group, united by a shared interest in creating an outdoor product, went out from there. Our efforts encompassed market research, concept ideation and refinement, manufacturing preparation, and prototype construction.
After our team validated our product’s market fit, we generated our product requirements and set out to create our design. The anatomy of our design worked out to where there were three subsystems, one for each group member. Each of these included the shower handle, the tank reservoir, and a pump to move water into the reservoir. I took ownership of the shower handle design.
After a multitude of iterations of sketching and computer-aided design (CAD) work, I arrived at what I thought was a feasible solution. I elected to utilize a thumb-controlled butterfly valve mechanism, allowing the user to control water flow with their thumb at the corner of the handle. I suspected the valve's simple geometry and low part count would translate to manufacturability and assembly. However, upon the first stage of prototyping, I quickly realized that the butterfly mechanism was unmanufacturable due to the overall scale of the handle, prompting a redesign.
I shifted the design towards a thumb-controlled ball valve to improve manufacturability and assembly time. Doing so slightly increased part count, but overall created a better seal along the stem of the valve. This project was not without its challenges. One of the primary hurdles was learning to use new equipment, such as the CNC mill, CNC lathe, and wire electrical discharge machine, all of which I had never used before. Using these tools was essential for creating precise components, but the learning curve required considerable time and effort. Fixturing for CNC milling and manual milling operations presented another significant challenge. Ensuring that small workpieces were securely and accurately positioned was critical for achieving the desired tolerances. This process involved a lot of trial and error to perfect machining setups and avoid any unwanted movement during machining.
Post-processing 3D-printed materials also posed difficulties. When attempting to tap the valve housings for a threaded connection between the nozzle and valve housing, the resin’s brittleness resulted in fracture of the material. Additionally, warping in some of the resin-printed parts prevented a proper seal between the valve housing faces. Unfortunately, our group did not meet our product requirements within the class's allotted time frame. However, several design changes could improve this prototype. First, designing threads directly into the 3D-printed valve housing would eliminate the need for tapping. Adjusting print orientations to maintain flat mating surfaces could address the warping issue, ensuring an effective seal between the valve housing halves. Additionally, consolidating the bottom pipe and valve housing assembly into a single part could reduce part count and overall complexity. Looking back, it also could have been more effective for our group to just purchase a thumb control handle rather than designing one ourselves, allowing us to focus more on the novel technology within our product. To access further documentation regarding this project, click the button below.
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