IELM 215. Mini Project. Topic: Design and fabrication of a USB stick Project administrative details: 1. Teams: Each project should be done in teams. Each team is composed of two lab groups (i.e. four students in total). 2. Deliverables: At the end of each project, you need to submit two deliverables - i - A completed prototype (see details below). - ii - A report (see details below). 3. Learning objectives: (i) Gain experience in basic product design process, including concept design, detailed design, and prototyping. (ii) Gain experience in project management, teamwork and communication (iii) Gain experience in technical communication. 4. Grading. The projects will be graded with a nominal maximum score of 100 points. Team mates share scores equally. Rules of scoring: [50 points]:Instructor, 15 for design, 15 for fabrication quality, 10 for report. [2x25 points]: Each TA will grade- 15 for design, 10 for fabrication quality. 5. Important dates and Project deadline Team formation: April 12. Please email your team groups to the TA by the deadline. Any lab groups who do not team up by this date will be assigned groups by the TA. Project and Report: The project and report can be submitted any time before the final exam. 6. Project work. You can freely use the Mfg Sys Lab and its computers to do your design and manufacturing planning work. You can use any equipment including FDM, CNC, Drill, Grinder, and other hand tools. Please make an appointment with the lab technician, Mr. Tin (ietin@ust.hk), if and when you need to use a manufacturing facility (CNC, FDM, etc.), You may need the help of the TA to complete CAD models using CATIA. Please make appointment with him, if possible, during scheduled lab hours of the weeks set aside for project work.

Task 1. HKUST 20th anniversary theme USB stick. There are many interesting USB memory sticks that are used as souvenirs and gifts. Below are images of two examples (there are many on the internet!)

(a) Wine bottle USB (b) Toy monster USB [source: www.designer-daily.com] Your objective is to design a USB stick to commemorate trhe 20th anniversary of HKUST. The only design constraints are: - Your design must have some reference to 20th anniversary, and it must either use HKUST landmarks (e.g. the UST logo, Red bird, etc.) or the School of Engg logo as a basis. - Your design must have at least three components: (i) a small USB card, (one piece will be provided to each group), (ii) A body holding the USB card. (iii) A cap that can cover the USB. You must design and produce a prototype. To fabricate the components, you may use any machine available in the lab, including the FDM machine, the CNC and other cutting machines, grinding wheels, other hand tools etc. If you need to source any special materials to make the prototype, please give the lab technicians (Mr. Tin) enough time for procurement. Task 2. At the end of the project, you must submit a project report that has the following: (a) One A-4 sheet (pdf format) including the User guide, Product specifications and a warranty form. (b) Scanned images of the important conceptual design sketches you made during the initial design phase. This should include the rejected ideas. (c) A clear statement (bullet points) of the reasons for selecting the final design.

(d) A clear statement (maximum 5 bullet points) of reasons for selection of the material and manufacturing process for each component. (e) CAD models of all the designed components (including the CAD files) and screen-shots (please convert to JPEG format, and reduce size of each image to max width, length of 1000 pixels) of the CAD model of the components and assembly. (f) Item-by-item listing of any process plan files you used for each component. The associated computer files (for example the STL files, GN-codes etc) should be attached as soft copies. No hard copy of the project report is required. You can email the soft copy directly to the instructor and the TAs. The title of your email should be: IELM 215 Project Report, Group xx. [xx is the group number that the TA will assign to you]. Some images for reference:

School of Engg logo 20th anniversary UST logo UST logo Sundial