Mustache Award

Summary Continued… It has a base dimension of 8.8 cm X 8.8 cm and a height fully completed of 15.1 cm with a width of 14 cm from the mustache. It is easy to carry around and proudly show off in your home or desk. 

Lesson plan and activity: 

The client requested a curriculum trophy to award to the most creative student for a project in their class. This trophy is awarded to a student that creates the best mustache after reading the biography of Friedrich Nietzsche. It is used as a playful way to engage people in the class work. 

Parts:

• Base Award - 
• Base Award Pin - 
• Cone Piece - 
• Mustache Pin - 
• Right Side Mustache -
• Left Side Mustache -

Assembly Instructions:

• Take the Base Award Pin and insert it into the Base Award for a tight fit. 
• Place the cone piece through the Base Award pin so that it sights on the Base Award. 
• Take the Mustache Pin and put it through one of the mustache sides. 
• Take the other mustache side and push it into the pin so that both mustache sides are now flush with each other
• Lastly, place the completed mustache on top of the base pin so that it sits on top of the cone.

Design Choices:

I initially had 4 mustaches and 4 base design choices sketched out on paper and pencil and showed them to my customer (teacher) for their finalization on which from there I would get started. 

I then decided to start building up the cylinder part of the base using an extruded circle but found that I wasn't getting the desired shape I wanted so I created a sketch that captured my imagination and then revolved that sketch.  

Once I had the cylinder and pillar details added I had to include filets to where the endcap semi-circles went so print orientation requirements would be met. 

I initially started to create the base in Solidworks with a base dimension of 6 cm X 6 cm. And once printed I found out that it was much too small when printed and held in hand. I decided to scale the whole base up by 1.47 besides the extruded cut for the base pin. The new base dimensions were 8.8 cm X 8.8 cm.  

Regarding the mustache I had to figure out a way to create it without it being too large for the 3D printer. The solution to this was to cut the mustache in half and print either half separately and then connect them with a pin. 

Once I cut the stache in half I made a circular cut-out slot for a pin but realized the mustache might rotate around when assembled so I scrapped that and then made a square-shaped pinhole. I also fileted both cuts so it would be easier to insert the pins. 

Once the main components were completed and printed, i needed to sand down the mustache slightly for a better fit.

The first rendition of the mustacche is shown below.

I noticed that the base beam needed to be larger so I increased the base beam's length from 4cm to 8cm.

This gave it a more aesthetically appealing look however I needed to cover up the protruding beam. That's where I came up with the idea to place a cone around the beam.

My first design was just a revolved cone but it was too boring so I redesigned another cone piece that was much more aesthetically appealing to fit the rest of the design. The final cone had a hole through it which was .54 by .54 cm across for an adjustable fit.