Sparton 600i Design Process

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    Design Process Report

    MP3 Docking Sound System

    Walter Dorwin Teague

    Sparton Series

    Lando Di Girolamo

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    Original Concept Sketch

    The first iteration of the Sparton style dock wasan 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

    http://www.thedecoblaster.com/http://www.thedecoblaster.com/http://www.thedecoblaster.com/
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    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 completeunderstanding of the scale issues

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    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

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    2nd 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.

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    New Concept Sketch

    The sketch mimicked the

    foam model in shape

    etc

    As I had already made the

    foam model I knew thescale.

    I then went into Solid works

    to start sorting out the

    proper model, including

    manufacturing strategyetc

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    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.

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    3rd Attempt CAD Model

    After reading through speaker forums andwood 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 amanufacturing 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 withoutresorting to Deco Blaster tactics.

    A fourth and final model was needed to

    resolve all issues.

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    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

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    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.

    4th/Final CAD Model

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    4th/Final 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 MDFsheets 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

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    4th/Final CAD Model

    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 stylingdecision 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 thatcradles it.

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    4th/Final CAD ModelTo 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

    I-Phone WellSecured with Screws

    Infar-Res Lens CoverSecured with Glue

    PCB Support ClipSecured with Glue

    Screw GussetsSecured with Glue

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    4th/Final CAD Model

    Bass PortsSecured with Screws

    PCB

    Support/ButtonsSecured with Screws

    Cloth FrameSecured with Snap inserts

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    4th/Final CAD Model

    The tech pack layout is fairly compact once all thecomponents 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.

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    4th/Final CAD Model

    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

    Screw Insert

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    4th/Final CAD Model

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

    snap connections.

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    4th/Final CAD Model

    Elevations with all

    tech components

    shown

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    Remote

    The remote for the final design, simply

    references the aesthetics of the dock,

    as well as the I-Phone 4.

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    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 withthe hole in the remote

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    Remote

    Securing the battery inside the batteryhousing 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 thebattery.

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    Computer Generated Render

    The final computer generated renders of the Docking station shows the materialsand 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

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