Wii Nunchuck Tape Dispenser

Summary

Wii would like to present the latest revolution in bizarre Video Game merchandising, the Wii Nunchuck Tape dispenser (pls dont sue me Nintendo).  This print comes in 2 parts, the main nunchuck,  and the roller section. It is a part of a set of 3 Wii themed office suppliies, or offiice suppliies. The other parts are a Wiimote pencil sharpener (perfect for your DK Banana pencil case) and a Balance board to hold your extra items. This project was made in collaboration with Vanya and Sriram.

Problem Statement:

Recent analysis by the Staples finance department has concluded that sales for desktop organization products have declined in recent years.  The company would like to ramp up their profits in this area by enhancing the aesthetic nature of these products.  

Your group has been hired to design a set of theme-based organizational products.  Your team will design a set of office supplies that are tied together with a common theme. You must be able to justify how the theme connects the products together.  The idea is that the customer will not want to buy just one; they will want to buy the whole set.

Each item in the set needed to fit within a 10X10X10cm area for printing, with limited supports and should be unique and artistic. The idea was for it to be a conversation starter. The set needed to have items that demonstrated the use of certain solidworks features, like lofts, revloves, circular patterns, and sweeps to give examples, to demonstrate mastery of the software. But each item did not need to show all features.

Assembly instructions:

You will need to print the base file, and the tape roller file.

1x blade or common tape razor, that is 0.03 cm thick and 1.5cm tall

1x roll of max 5mm deep and 19.5 mm wide office tape

Tape roller:

To assemble the tape roller you will need to push each of the smaller circles into each end of the main roller.

Then insert the roll of tape into the middle of the roller

Main body:

Slide the blade into its joystick slit with the cutting part facing up.

Insert the assembled tape roller into its hole behind the stick, ensuring the sides line up with the guide slots.

Design Changes:

The initial paper sketches involved a loft made out of 4 separate sketches of different sizes of the same shape, in order to match the shape of a nunchuck. This was then changed to two sketches with a center line that followed the curve of a nunchuck for the first solidworks model, which was changed to involve an altered centerline, and two guide curves (one for the top curve, and one for the more complex bottom curve). This final change would result in every other step needing altered dimensions or other changes.

Paper sketch:

Old Loft:

Final Loft:

After settling on an initial shape, the C and Z button shapes (a circle and rectangle respectively) were extruded, with their positions and sizes changing several times as the shape of the body was altered, with major changes relating to the distance between each button needing to be closer.

The Z button had a major change in its size, as its original size was found to be too large compared to the C button, this resulted in its dimensions being cut in half.

Old Buttons:

New Buttons:

After this the shape of the joystick was made with a revolve, this underwent few changes, with most relating to some points of the sketch being fixed to a curve of the body, with said points needing to be adjusted to the location of the new curve.  

Old Sketch:

Old Revolve:

Final Sketch and Model:

Then the first of many fillets occurred, this one being for the sides of the body to give the curve, this fillet needed to be fixed after the final change to the loft occurred, as a filleted side was removed.

Old Fillet:

new fillet:

The first cut for the blade was made, however the initial dimensions from paper sketches was too large, however after some tweaks and a remeasure of a razor, the right dimensions were found. During the final loft redesign, the dimensions of this cut needed to be redefined to match the new curve. The orginal cut had its width set to 0.4cm instead of 0.04 cm, which made the gap for the blade to slide into too large, this was quickly fixed. The height of the cut was first shortened to 1.32cm and then changed to 1.40 cm.

Paper Sketch:

Old Cut:

Fixed Old Cut:

Final Cut and sketch:

Then the entire model was scaled by 1.5x, however the top of the stick would not move to the new position when scaled, this was fixed with a scale based on origin.

old scale:

new scale:

The tape holder was then cut out using an cut extrude and a circle with a radius of 1.22 cm and a offset of This circle would be moved around during the loft changes as it was not fully defined. The offset was determined by finding the thickness of the body, subtracting it by 2 (the desired thickness of the cut) and then halfing it.

Paper Sketches:

Old Cut:

New Cut:

Then the front of the nunchuck body was filleted to round out the edge, this fillet would be affected by the final loft change.

Old Fillet:

Final Fillet:

Then the extra cut for the razor slit to accommodate for the bottom horizontal section of certain blades was made and given some smart dimensions, Many changes occurred after the final loft change. The placement of this box was determined using a smart dimension from the top right corner of the box to the top of the stick (later done with a point placed at the top of the stick after the final loft change)

Old Cut:

Final Cut:

Two feet, one for the front and one for the back, were then made using 2 boss extrudes. The first made a single rectangle for the back of the body, and a tall rectangle for the higher front section. The second sketch gave a flat bottom for the front. This feet system would not last and would be replaced with a single boss extrude base for the entire body.

Old feet sketches:

Old Feet Model:

This base is made up of 4 lines, with the top points going inside the body by the curved sections, and the bottom two are placed to be horizontal to each other.

Old Base:

New Base:

The C button was then filleted and given a cut for its letter. This letter would be moved after any alterations to its button

Image:

The Z button was then filleted and given its letter cut. Like the C button, its cut was also moved when the button was moved.

Image:

A tape roller was then made, originally consisting of a large tube that would go through two holes made on each wall of the tape holder.

Holes:

Tube:

The radius of the tube was identical to the radius of the holes, which could have caused issues.

However after the model was given a pass by the engineering teacher. It was suggested that the roller needed to be redesigned to slide into the tape section from above. This was done by making a .10 cm cut into each side wall of the tape holder. These cuts had a L shape to allow the tape to slide in, and then be held in place while the tape is moved forward when pulled. With these changes occurring after the final loft change.

Slots:

To accommodate this new design, a new roller was made consisting of a center cylinder to hold the tape, with one small circle to insert on each end to allow the tape to roll inside the guide curves. These extra circles were 0.6 cm tall when extruded, this allowed for them to stick out by .1cm from the main roller when inserted (the main roller had two 0.5cm cuts on each end).

Main Tube and its cuts:

Side pieces: