From Sketch to Print: Designing a Custom 3D-Printed Clipboard Pen Holder

Here I go again, making either something better or just another variation for the sake of it. I designed a clipboard pencil holder previously. Now I thought of holding a pen. The pen I frequently use. 

Not because I like it, but because I bought them in bulk. And really, they are not too bad. Else why would I bother making a clipboard pen holder just for this specific pen? 

To begin, I always start with a sketch of the most basic potential holder design. One that first comes to my mind. Before that, I would sketch the cross-section of the pen, then the holder 'gripping' it. See Fig. 1. 

Figure 1: A quick few minutes Pen Grip Sketch

As I sketch, a mental calculation simultaneously refines and considers subtle details like a ‘clip grip’ at the pen’s end. This provides extra hold while enhancing its overall aesthetics.

I’ve determined the top of the ‘U’ shaped grip should slightly pass the pen’s centre for a better grip.  The other dimensions like the flat section for attaching to the note pad’s reverser are simply estimated.

  

Figure 2: Series of photos showing the pen-grip in action

Figure 2 displays a batch of photos showing the 3D-printed pen grip in real life.  When placed correctly at a specific angle, the pen clicks neatly into the grip with a satisfying ‘click’.  It remains securely fixed even with light handling. However, any nudge on the un-gripped pen section dislodges it. Despite this, the pen fits the grip perfectly.

Figure 3: Tinkercad model of the second iteration

I felt the initial print could have been improved.  For the next version I doubled the horizontal grip section’s length and added slots to the flat section.  The Tinkercad model is shown in Figure 3.

Figure 4: The new improved pen-grip design

Figure 4 shows a comparison between the first and second 3D-printed pen grip designs.  Visually, the second variation appears to offer a better grip than the shorter one.  It’s easy to guess which I used on my notebook.

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How to Avoid Sizing Mistakes in 3D Design: Model Accessories First

In this post, I'll show you how I designed and printed a coffee bean grinder, brush, and measuring spoon holder. See Fig. 1.

Fig. 1

I've seen too many instances where a student's completed 3D design turned out to be the wrong size despite looking proportionately correct.

This happens because students often start by 3D modeling their design as the first step. But what's the problem?

The moment I sketch the accessories (items or objects to be held or stored) into their design, the holder almost always ends up looking tiny compared with the accessories. What happens next usually requires extensive modification, sometimes even re-modeling the entire 3D design.

This is how to avoid making the same mistake ever again:

• Always model the items to be held or stored first.
• Then model the design that will hold or store those items.

Here are the steps:

• Firstly, make a list of the items you want to hold or store.
• Secondly, make notes about their dimensions. I call these the "Critical Dimensions". (see Fig. 2)
• Next, before modeling your design, model all the accessories first (see Fig. 3).
• You don't have to model them exactly as they look.
• Use basic geometric forms to represent each item.
• Finally, model the design. Then place the items into the model and see if they fit (see Fig. 3).

Fig. 2: Critical Dimensions of the coffee grinder, brush and scoop

Fig. 3: Modeling the accessories first (see the three items on the right hand side)

Fig. 4 shows the coffee grinder (round cylinder), the brush (narrow cylinder), and the scoop, all positioned on the holder. These are their final positions after a few rounds of adjustment. You can see that all the items fit nicely on the holder. The holder not only looks proportionate, but it is also the correct size.

The image on the right shows the actual 3D-printed holder with the accessories in place. They all fit nicely.

Fig. 4: 

Left: The Tinkercad Model. 

Right: The actual printed design.

Conclusion

It is not necessary to model all the items or accessories before modeling your design. In fact, if you model your design using actual dimensions during the development phase, you may be able to get it right on the first attempt.

However, in my experience, many students either miss the instruction that their design must be modeled according to its actual proposed size, or they are simply too excited to see their design in 3D and forget about the dimensions altogether.

Whatever the case, I believe it is good practice to model the accessories first. This gives the designer another opportunity to evaluate whether the placement of the accessories is final or requires further adjustment.

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Size and Proportions: When Designing Holders and Items (to hold)

In this video I chat about practical tips and guides related to sketching ideas with the items to hold or store, or anything. 

A common problem and sight in students’ journal when they sketch or draw, more often than not, they do not get the relative size and proportions right. Lacking of an awareness is one possibility. 

Example of a Paper Clip Holder

Look at the example above, can you find the paper clips? Do you have an idea how BIG this Eiffel Towel will be in real life? For a Paper Clip holder the design is an oversize. An overkill. But I can almost guarantee that the student who sketched this would not have any idea that it is so.

Sketches usually show UNUSUALLY OVERSIZED HOLDERS with extremely tiny items, whatever they may be, that the holders are supposed to hold.

Watch the “Design & Coursework Chat” video to learn about what’s going on. How to identify out of proportion sketches when the size of the holder does not match the items to be held. How to overcome this? What are some general tips and guides to overcome this common problem.

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Secondary 2: Dining Storage Accessories Project - Design Considerations & Limitations + Design Specifications

This part of the design process is right after you have written your Design Situation and Design Brief. 

Design Considerations and Limitations

The 'Design Considerations and Limitations' (or Constraints) can be liken as 'what factors should I consider'. Thinking of it in this way will make completing this task slightly easier.

Limitations or Constraints refers to factors that will 'restrict' you in making the product. Some factors that are considered 'limitations' or 'constrains' or 'restrictions' are for example, time, cost, size, technological feasibility (i.e. the available type of machines and tools in the school design workshop), so on and so forth.

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Imagine you need to plan for a class outing. You will need to plan and create a list of stuffs you need to do (or consider bringing). You do not need to go into the details yet but generating an initial list from which you can work out in details later. For example, you'll need to consider to 'bring some bottled drinks', then 'plan the routes to the destination', etc. 

In a similar way, you would have already chosen a particular type of 'storage' or 'holder' you want to design for. Recall your Design Brief. Now think, "I want to design and make a ..." so "what are the things/factors I must 'consider'?"

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Examples of common factors related to a proposed project

'I must consider..."

'functionality': what you want your product to do or how you want your product to work)

'size': this could be the area of the space you want your product to be placed, or the overall size of the product you will eventually make.

'materials': this can refer to the type of materials that you are given or the quantity.

'time': in a project you are usually given a period of time to complete your work. so considering the time you have is important as it will influence the way you spend your time and design your product. so that you can complete it in time.

etc. You can read more about the other factors by referring to your textbook. 

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Critical Dimensions:

The critical dimension is part of research and it is an important one to consider. For example, I want to design and make a 'business card' holder. Before I begin generating ideas and such, I got to have some important data on standby for me to make some design decisions later. 

One common dimension that you must have is the dimensions of the 'things' you plan to hold or store. If I plan to make a holder / storage for business cards, I should research on the sizes of a typical business cards. I might go as far as measuring the thickness of a single card, or multiples of 5 cards all the way to 20 cards, or so. The more variety of ways to measure and better. Because I do not know if I will need them. Who know?

If yours is a straw holder, then measure the straws. A single one and a bunch of them. If yours is a spoon and fork holder, then measure them too. For the rest it is the same. Measure them. Weigh them. Whatever data you can record.

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Design Specifications

I like to think of Design Specifications as a 'wish list'. 

It sounds more 'friendly' and less daunting than 'Design Specifications'. So technical.

The design specifications are a list of very specific instructions that comes from your list of design considerations. Can you still remember design considerations as a 'list' of factors which you need to 'consider'? They were not detailed at all. Or not detailed 'yet'. 

When I say 'I need to consider the quantity of cards for the business card holder', I have not specified 'how many'. In design specifications is where you state 'how many'. In design specifications you will also state how 'big / small' (e.g. area or volume), how 'cheap / expensive'(e.g. cost), how 'long / short' (e.g. time or length), how 'heavy / light' (e.g. weight), etc.

In the example above, I will be very specific to say, 

'The product must hold (at least) 15 business cards'. 

Nothing more than 15. The number 15 is a very specific number.

You can also put numbers on factors that is concerning efficiency, or fast or quickly or ease o use. You use 'time' to quantify efficiency. You can say,

 'The product must be easy to use. The user must not take more than 5 seconds to refill all the 15 business cards into the holder when it is empty'.

Shown above are two examples on how you can complete your Design Specifications. 

Refer to your textbook if you still have problems completing this section.