Burger - paper clip holder

this semi-realistic burger is not only good-looking, but it also doubles as storage for all your paper clips. The burger is around 8 cm tall and 10 cm wide, the perfect size for any desk!

Final goal

My partners, Paul and John (The3rdJohn_2915693 and @Pauligee_2915685) and I worked together with the ultimate goal of creating four themed office supply products. Our theme was fast food, and we created:

1. A hot dog tape dispenser
2. A burger paper clip holder
3. A corndog pencil sharpener
4. A French fry pencil holder

Constraints

1. You will be constructing an actual-size model of your product in SolidWorks.
2. Your items must be interesting to look at and unique - a conversation starter.  An individual walking by would do a double take to more closely examine the amazingly artistic item you’ve created.
3. Your items must contain examples of ALL FOUR main Features:  Extrusion, Revolve, Sweep, Loft. 
   1. All Features DO NOT need to be present in each piece, just amongst the set
4. Your items must take advantage of at least one of: Circular Pattern, Linear Pattern, Sketch-Driven Pattern, Mirror 
   1. All Features DO NOT  need to be present in each piece, just amongst the set
5. ALL of your items must take advantage of Filleting and maybe Chamfering
6. Each piece you design should fit within a 10cm x 10cm x 10cm cube, or 1000 cm3 volume equivalent.
   1. Each item can be multiple pieces to be assembled for easier printing
   2. Maximum length in any direction is limited to 20cm (slightly negotiable, MAYBE 27cm max)
7. Should be 3D printable with limited/no supports, (each item can be multiple assemblable pieces to help with this)

Design steps

First, we started with a paper sketch of what we wanted to begin with:

Once we had created a full plan for creating our burger, it was time to begin in SolidWorks. We started with this sketch:

This side profile of the burger is what we revolve boss/base around to create the full shape of the burger. This is what the original burger looked like:

Once we had the shape of the burger, we hollowed it out. Next, we used the cut extrude tool in order the very slightly separate the top bun from the rest of the body. Then, we used the move body tool to separate the bodies further. This is what it looked like after we separated them:

After that, we created a circular sketch on the bottom of the top bun to create the part that allows the two bodies to stick together. Once we boss extruded it, it looked like this:

We created a smaller circular sketch inside and extruded cut it. It looked like this:

Now that the burger was almost done, we decided to add sesame seeds to the bun. To do this, we created a sketch with small sesame seed shapes onto the bottom of the top bun, and boss extruded them upwards. It looked like this:

In the image above, there is a blue sketch above the burger. We used that sketch to revolve cut the excess sesame seed material, so that it would look like this:

Once we finished adding the sesame seeds, we decided to add a “logo” onto the bottom of the burger. Our team name was Japohn, a combo of all of our names, so it says Japohn Inc. We added this to the other products as well:

Design changes/choices

Designing the burger was fairly straightforward. For the most part, we didn’t encounter any major issues with our design, although we did make design changes to make it look better. The first choice was in hollowing out the burger. At first, we tried creating a solid burger, then moving the lid, and then extruded cutting it, but decided it would be easier to just make the burger hollow from the first sketch that we revolved. The new choice looked like this: 

This worked better and made it easier to change dimensions when we wanted to. 

The next change we made was to the text at the bottom. After we finished the burger and all the other products, we realized we should have made our logo with uniform text. This was difficult because all of the places we had text were different sizes and needed different lengths and heights. Below is the text before we changed the font:

Once we printed the burger, we removed the supports:

Images of the final print:

Our french fry holder:

 Our corndog:

and our hot dog: