3D Printed Object: Speaker Stand Handle Knob

For the 3D Printed Object Assignment, I chose to design and print a replacement handle knob for my speaker stand, which had recently broken. I used the web-based CAD software, Onshape, along with the Prusa 3D printers available in the MILL, to create my model.

Design

Sketches for alternative designs

For my initial design process, I sketched out several variations to decide whether to innovate on the original design of the speaker stand or to build upon it. After experimenting with different shapes and grips, I ultimately chose to refine the existing design and create my own version. The handle needed to fit a 1.2 cm hex bolt, so I carefully measured and determined the required dimensions. Designing the handle turned out to be straightforward, primarily using Onshape’s extrude function and Boolean difference to shape it. To enhance the handle’s appearance, I applied fillets to smooth out the edges, giving it a more finished look.

My Speaker Stand Knob Design on Onshape

Analysis

Cardboard Prototype for the Speaker Stand Knob

For the prototype, I concentrated on determining the most comfortable grip size, which I found to be about 5 cm in diameter. I started with a low-fidelity cardboard prototype to get a sense of the size in real life. Then I measured out the dimensions of the hex bold on my speaker stand to get all the necessary measurements. After getting the sizing right, I updated my STL file accordingly and used the PRUSA slicer tool to generate the GCODE. My main priorities for this assignment were feasibility and usability. When designing the handle, I made sure it could easily attach to the hex bolt on my stand. I kept the tolerances tight, aiming for a snug fit that would allow the handle to turn the bolt effortlessly.

Reflection

Final Design on the Speaker Stand

I chose to design and print this Speaker Stand Handle Knob because I desperately needed it; ever since the original broke, I’ve been awkwardly using a wrench to set up my stand. The real challenge lay in crafting a simplified yet functional design, which I managed to achieve after carefully measuring my stand dimensions. While printing the final model, I encountered a hiccup when the roll of PLA fell off the printer, leading to a malfunction causing me to reprint. Fortunately, that was the only major issue.

Using Onshape proved to be straightforward and user-friendly, but I did struggle a bit with figuring out the optimal printing settings and properties, which were crucial for the outcome of the final product. Overall, the process was enjoyable, and I am glad that I could turn this assignment into an opportunity to create something I genuinely needed. If I were to do it again, I would focus on making the handle more ergonomic to enhance comfort and functionality.

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