Open Sesame Challenge Preliminary Design proposal (Concept_vers1)1

Last crawled date: 1 year, 11 months ago

The design intent here was to focus on keeping a consistent and similar design with some of the other winning entries chosen in previous Blackboard challenges. It’s important to build a brand by having some design similarities among the product families. Since this is another card reader device, I’ve used Blackboards handheld reader (designed by David Franklin, from here on GrabCad,
https://grabcad.com/library/bb-transact-1) as inspiration for this design. I tried to incorporate some of the design and style cues of his design while adding my own flare and innovation. If you were to look at the two products side by side, you would know that they belong the same product family or company. Just like you can tell that a Logitech product is made by Logitech even though they might be completely different things with different functions.

I only realized that the antenna was going to be sandwiched with the main board after this design was finished. So in this case, I have designed it with the antenna as a separate board to the left. I have made a revised vers that I will add later that will have the revised, more accurate architecture with the sandwiched board. The designs and files I am offering are NOT JUST PRETTY surface models, all of my designs and model files are basically ready to mold, I design them as accurately as I can. There might be a need to change a few screw holes around, move a few ribs here and there, add a fillet or two, to meet your needs but otherwise they are designed with drafts and molding in mind.

When designing this, I reflected on the design considerations and tried to address all of them. Obviously it’s a beautiful design, but I also have considered its DURABILITY, RESISTANCE TO VANDALISM, ENVIRONMENT. I will explain further below, AND I also invite you to review the slides for better visual reference.

DURABILITY

I used .07” main wall thickness on the bottom half and .065” on the cover. These are descent thicknesses and a good balance between cost and durability. The weather protection guard is to be molded of durable rubber, it’s flexible and durable, it won’t crack or break.

VANDAL RESISTANT

The concept here is to use a custom aluminum backing plate as your foundation plate, this can be adapted any surface and it is screwed in place with special tamper proof screws(size m5or m6). Prior to this plate being installed, from behind, screws are inserted through the plate and bottom half of the case and then are threaded into the coverplate, thus closing and tightening the whole unit. The coverplate is designed with a lip so it fits over the bottom half to provide a weather proof seal. Because these screws for the case can only be accessed when the aluminum plate is off, there’s no way to get into the card reader unit without taking the aluminum plate off (which has the special tamper proof screws)

ENVIRONMENT

As noted above, the design intent was to keep a consistant aesthetic with some of the other family of card reader products but I also wanted to keep the lines and forms fairly conservative and straight considering it’s intended use as a door card reader. It’s an environment that see’s more conservative and more “industrial” design aesthetics. Not really the place for Apple Mac design styling. So although the design does have cues from David’s Franklin’s hand card reader, it’s overall more conservative and industrial in nature, straighter lines, simpler overall form etc.

**some notes on the features

I included a mag stripe reader in addition to the touch reader. All my designs are designed with simplicity of manufacturing in mind. There are literally a million ways we could about designing a case but budget will affect what can be done. There is no glass, no touch LED panels, no overmolding. In this particular design I only used two plastic halves which can be made with a simple two part pull mold for each part. This reduces the cost of the tooling greatly. Yet I tried not to sacrifice in terms of design aesthetics. I also tried to keep most of the parts for the CB off the shelf so the keyboard module is a fairly standard design, some slight alterations might need to be made depending on which model is chosen but overall shouldn’t be difficult to find vs. designing a complete custom keypad system. The LED’s and lenses can be bought off the shelf, or worst case the lense covers can be molded very inexpensively.

OVERALL DIMENSIONS:
5.3”L X 3.2”W X .85”h

There are two backplates, one short one for interior installation and one longer one for use with the rubber shroud for exterior installation.

As mentioned, I will be added another similar design to this that will be slightly different in dimensions(thinner) and tamperproof function so stay tuned.

I've uploaded .step and .iges files. I can make the native files available upon request. I've saved the files in .stl format but understand that I did not design them for FDM printing, they will most likely need to be tweaked for FDM printing, they will need to be run through a mesh editor, resized etc. I really didn't focus on making them 3D printable. The .step files should be good to go for injection molding.