Peli Paul Ghost Clip

Summary Continued : 

 Personalize it by choosing your favorite color and engraving your initials for a custom touch. Perfect for brightening up your office, desk, and can even act as a fun household decoration. I collaborated with Eli on this project. Follow his Printables page at (https://www.printables.com/@Eli_2917978).

Objective:

With a partner (or partners), you will recreate your ghost clip using the Solidworks 3D printing software. You and your partner MUST have identical files that you create by collaborating on each consecutive step, taking the time to make sure you and your partner follow your procedure at the same pace.

Assembly/Construction Procedure:

 First steps-

1. Click on “New” and then on “Part”,  then space and click on the front side of the cube. Make sure you are in sketch and not features. Navigate to the front plane.
2. Using the center point rectangle tool, create a constraint box 13 cm by 6cm centered around the origin. This box will contain all the features of the Ghost Clip. Also, make sure to have midpoint guidelines. Make all of the lines construction lines. You can do this by pressing “construction geometry” and then selecting each line you want to make into a construction line.
3. Make a horizontal construction line 0.8 cm lower than the top of the constraint box.
4. Now make 6 triangles, using the solid line tool, with their base on the bottom construction line and with their vertex on the top of the box. Space them out evenly. There should be 3 triangles on each side, with the last point of the 3rd one on the midpoint guideline created by the box.
5. Now make their sides equal using the equal relation (after selecting each side using ctrl then clicking on them) so each base should be 1cm and each other side should be 0.94 cm. 

The bottom-

1. For the bottom, make a horizontal construction line 1 cm above the bottom of the constraint box.
2. Now make 3 circles, each with a radius of 1 cm (or diameter of 2cm). They should be equally spaced, touching each other, and tangent to the horizontal construction line, as their diameter is 2 cm while the base is 6cm. 
3. Now select the Power Trim in the Trim Entities tool, and trim the top part of the circles so only the part beneath the construction line is left, leaving 3 equal semicircles.

The eyes-

1. For the eyes, make a horizontal construction line 2.9cm beneath the top of the constraint box.
2.  Now, spaced 1.7 cm from the left side, make a circle with a radius of 0.6cm or a diameter of 1.2cm. 
3. Now, using the Mirror Entities tool, select the circle and reflect it over the vertical construction line made by the midpoint guideline of the constraint box. 
4. Make sure the eyes are equally sized and both on the construction line we made before it, the same distance from the left and right of the sides of the box.

The Mouth-

1. Make a vertical construction 4 cm long, 5 cm below the top of the box, and 1.5 cm from the side.  It should reach around 9 cm below the top of the box.
2.  Now, use the Mirror Entities tool to mirror this line across the vertical midpoint guideline.
3. Next, we connect the 2 lines with a tangent arc (connect the bottom points of the line) . It should have a radius of 1.5 cm, and be a perfect semicircle. Now change every line made for the mouth into a construction line.
4. Finally, we use the Offset Entities command to circumscribe the construction lines by 0.3 cm. (Make sure to enable Cap Ends with Arcs and Bidirectional.
5. Make a vertical line going from the construction line 0.8 below the top of the box all the way to the construction line 1 cm above the bottom, and watch everything fill up!

 VIDEO PROCEDURE : Peli Instructional Ghost Clip Video

Design Choices:

 Since the assignment was to replicate the Ghost, me and Eli decided to make a sketch of the Ghost before designing it in Solidworks. We used a ruler to measure the key elements of the Ghost like the length, width, and depth. We measured the location of certain points on the Ghost to accurately construct the location of the mouth, eyes, and triangles in Solidworks. We encountered very few problems with our design process. 

Sketch Plan on Paper:

Design Change Number 1: 

We had an issue with the semi-circles being over defined after using the Power Trim tool. We resolved this issue by preceding a few steps to when we tried to define the radius of the full circle. We then used the power trim tool to crop the top half of the circles and then define them rather than the other way around. This simple fix allowed us to keep moving forward in our design process.

Design Change Number 2:

We had an issue with the height of the mouth because we had made it slightly too long. We easily resolved this issue by decreasing the height of the vertical section of the mouth from 4.5 to 4 cm. This allowed our Ghost to match up perfectly with the reference Ghost clip.

Conclusion-

 Me and Eli achieved almost identical models with the example Ghost clip. Two minor differences were with the eyes and the height of the base of the triangles. The eyes on our model were slightly too low compared to the example. We should have reduced the distance from the top of the constraint to the eyes from 2.9 cm to 2.8 cm. The base of the triangles were a bit too high on our model compared to the example. We should have reduced the height of the base of the triangles from 0.8 cm to 0.7 cm. Overall we are very proud about how our model turned out and we hope you guys will like making your own Ghost clip as well!