retractable earphone case

Design & Technology | Student number: 25829018

The Retractable Earphone Case allows you to say goodbye to tangled and damaged earphones. The earphones are protected in a strong manufactured plastic frame where they are kept neat and safe until you’re ready to listen to some more music.

RETRACTABLE EARPHONE CASE

Retractable Earphone Case

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Contents PROJECT PROPOSAL AND PROJECT MANAGEMENT ........................................................................... 3

Project Proposal ............................................................................................................................ 4

Identification and exploration of the need ................................................................................. 4

Areas of Investigation .................................................................................................................... 6

Criteria Established to Evaluate Success ......................................................................................... 7

Time Plan ...................................................................................................................................... 8

Action Plan .................................................................................................................................. 13

Finance Plan ................................................................................................................................ 23

PROJECT DEVELOPMENT AND REALISATION .................................................................................... 24

Research...................................................................................................................................... 25

Research of Existing Designs .................................................................................................... 25

Research from Areas of Investigation ....................................................................................... 30

Tests ........................................................................................................................................ 34

Application of Conclusions ........................................................................................................... 42

Consideration of Design Factors................................................................................................... 44

Idea Generation ........................................................................................................................... 46

Overall Designs ........................................................................................................................ 46

Inner Case Designs ................................................................................................................... 50

Phone Case Designs ................................................................................................................. 54

Identification and Justification of Ideas and Resources ................................................................ 58

Realisation of Design Solution ...................................................................................................... 60

EVALUATION ................................................................................................................................... 73

Evaluation of Functional and Aesthetic Aspects of the Design ...................................................... 75

Impact of the Project on the Individual, Society and the Environment ......................................... 76

Relationship of the Project to the Project Proposal ...................................................................... 78

Ongoing Evaluation:

This is the method I will be using throughout my folio to highlight my ongoing

evaluation comments.


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PROJECT

PROPOSAL AND

PROJECT

MANAGEMENT

This graph clearly shoes that

listening to music is the

favourite leisure activity for

11-16 year old. Most of

these children would listen

through earphones.


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Project Proposal

Identification and exploration of the need

Situation

So many people listen to music nowadays, and most of the time it’s through earphones connected to

a phone. Earphones are generally fairly delicate, particularly the cord, therefore they need to be

protected. I go through a significant amount of earphones, forcing me to have to go and purchase a

new pair of earphones every few months simply because they have broken.

Earphones are expensive products, especially the durable and efficient designs. A good pair of

earphones can cost anywhere between 40 and 120 dollars. This is too much money to pay if the

earphones aren’t going to last longer than a month or two.

The cord is always subject to getting tangled in your pocket, or in your bag. This then leads to

continuously having to untangle your earphones, which is time that doesn’t have to be wasted.

Something to protect the earphones when they are not being used would limit the damage to

earphones and lead to consumers enjoying music more because they’re not worried about damaging

their earphones.

There are already a few products on the market that fulfil the situation:

Standalone Products – These are products that the earphones simply wrap around,

protecting the earphone cord from getting tangled and damaged when not in use.

Automatic Retractable Standalone Products – These products, with a simple pull or tug

automatically retract the earphone cord back inside the case protecting it from getting

tangled or damaged when not in use.

Automatic Retractable Phone Cases – Earphones are built into a retractable device that is on

the phone case itself. This allows for earphones to be protected and stored with the phone

at all times


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Proposal

In response to the need I have identified in my Situation, I am proposing to design and construct a

product that can be used as a storage facility for earphones. I will look to make this a portable

product that can be used on the go, and with the potential for wide-spread marketing and

distribution after I graduate from school.

The solution will:

Prevent the earphones from getting tangled when they are not in use.

Not only make it easier to use earphones, it will protect them also.

Have to be small and compact so that it doesn’t become a nuisance to use or carry, whilst

still being easy to use and durable.

Be a stylish and aesthetically pleasing accessory for Smartphone users.

To differentiate my product from others already on the market, I am

looking to explore a range of formats to incorporate a retracting storage

mechanism that allows for a wide range of earphones to be used with

the product. The retractable earphone case designs that already exist in

the market today are all unable to use a variety of earphones. Therefore

the case can only be used with the earphones installed into it. If the

earphones were to break in these cases, then the design would not be of

any use. Also, if the consumer would like to change or improve

earphones they wouldn’t be able to still use that case.

By installing into a phone case a pair of earphones that cannot be swapped, it leads to the product

being very expensive as the customer is paying for both the earphones and the case. All individuals

have different preferences depending on which earphones they prefer such as:

Specific buds or ear pieces

Quality of earphones

Appearance of earphones

Size and shape of earbuds

Preferred cord style and length

Brand of earphones

The consumer is unable to use the specific pair of earphones that they prefer in these cases as the

consumer must use the installed pair of earphones. For some, this ‘one size fits all’ approach won’t

be appropriate.

DESIGN BRIEF: To design and construct an earphone storage solution for

Smartphone users that can be used with a wide range of earphones


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Areas of Investigation

What Why How Where

Existing Designs

So that I can understand what is already on the market so I can differentiate my product. As well as providing inspiration by how products successfully function.

I will scout the internet for any designs that are similar to what I’m looking to do. I will also ask friends and family if they have/know of any similar designs.

I can scout for designs on designing websites on the internet at home and at school. I’ll have to arrange to talk to any friends or family that could provide an intelligent opinion.

Materials To ensure that I select materials that would be the most durable and reliable for the product’s intended use. The materials also need to be reasonably aesthetically pleasing and environmentally sustainable.

I will gather the professional opinion from experts at engineering firms like Albury Precision Engineering. I’ll combine this with research on the properties of materials on the internet.

I can contact engineering firms on the phone, I may also need to go into their workshop to talk more in-depth about my design. Research on the internet can be done either at home or at school.

Creo Elements and

the 3D printer

So that I am able to make a more professional design on the computer and then produce prototypes that can be combined with detailed sketches.

For Creo, I will complete a simple training exercise that my teacher has. My teacher will also explain the processes of the 3D printer.

I will have to complete this at school, so that the teacher is there whenever I get stuck or need to ask a question. After training I can use creo at home.

Safety To ensure the product isn’t dangerous to the user or others in production and in use.

I will test my prototypes to see if they endanger anyone when they are in use.

The prototypes will be printed at school. They will be tested at either school or at home.

Security To ensure the phone and earphones are well protected and not damaged while in use.

By using earphones and a phone with a variety of my plastic prototypes.

The prototypes will be printed at school. I can test them either at school or at home.

Function So that the design effectively operates and is easy to use by the target audience without damaging the phone or earphones.

I will make a range of different plastic prototypes to ensure that I select the most efficient solution to the situation.

The prototypes will be printed at school, and then they will be compared either at school or at home.

Durability So that I know how to structure the design so that it is able to withstand the constant everyday use without breaking or wearing away.

The prototypes will determine which design is the most durable. I will also conduct research on the most durable and reliable material

The prototypes will be printed at school, then they will be tested to see which design is the strongest and most appropriate either at school or at home.


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Criteria Established to Evaluate Success

To be deemed successful my design must fulfil the design brief and be a solution to the situation.

Therefore the product needs to be a durable and reliable, yet aesthetically pleasing storage system

for earphones. For my product to be deemed successful it must achieve high standards in the

following areas:

Function:

The function of the design is to protect earphones from getting easily damaged and tangled. The

earphones should be easy to get out and use and easy to store after use. The product must not limit

how Smartphones can be easily used and carried; therefore the size needs to be appropriate. Many

different shapes, sizes and types of earphones must be able to be used with the product.

Aesthetics:

Aesthetics is crucial for the product. Whether it is an accessory that can be attached to the

Smartphone or a phone case, it needs to be aesthetically pleasing to catch the eye of a possible

customer. If the product isn’t aesthetically pleasing then it’s definitely not going to have any chance

against substitute goods as customers will choose the more attractive design.

Quality:

The quality of the product needs to be of a high standard. The level of quality needs to be high so

that the product will last for an acceptable amount of time. The product will have to protect the

earphones and the phone, whilst still being durable enough itself. The consistency of quality is also

important as there may be possibility of mass production of the product after completion, so it’s

vital that each copy is the exact same level of quality as the original.

Ergonomics:

The ergonomics of the design must be incredibly accurate to ensure success. The design must suit

the phone or earphones it is going to be used with. If the design is the incorrect size or shape then it

won’t work with the selected phone or earphones, leading to the whole product being unsuccessful.

The design needs to be simple enough to use so that it can be easily used by everyone.

Cost:

If I’m just making one copy, the cost of the product shouldn’t be that important as it will not be very

expensive. However, if I decide to go into wide spread marketing and distribution of my product

after completion, then the cost is incredibly important. The costs for the materials, labour and

advertising of the product would have to be low enough so that the price of the product isn’t too

high, so that it can compete with substitute goods. The costs need to be minimised to ensure that

the product can be sold so that the maximum profit is made.

Obsolescence:

My design should be able to be altered when technology improves. For example, when the next

generation of iPhones come out, the case needs to be able to be easily manipulated so that it is still

the most efficient product on the market. It can’t just be made to suit a particular design of phone

that will become obsolete in 12 months time.


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Time Plan

Initial Overall Time Plan:

Term

4, 2013 1, 2014 2, 2014 3, 2014

Research & Development

Realisation

Evaluation

Hopefully research & development is completed by the end of Term 4, however if it isn’t I have

allowed half of term 1 to complete it. This will allow me to begin the construction process of my

design just after the start of Term 1 next year and complete Realisation halfway through term 3. It is

important to evaluate the project at all times of the design process, therefore I will be doing it in each

term particularly at the start and end of each term.

Actual Overall Time Use:

Term Term 4, 2013

Term 1, 2014 Term 2, 2014 Term 3, 2014


Realisation

Evaluation

My project requires a significant amount more research & development than I initially expected. The

design process, including making the all the prototypes have taken most of my year of work. To make

the design function correctly, and run as efficiently as possible, it requires a massive amount of

designing and researching to reach an appropriate design solution. The realisation process of the

final design didn’t take very long as I got Albury Precision Engineering to manufacture my design and

it was basically finished. I evaluated my design in the final stages of the project, and finished the

remaining parts of my folio.


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Term 4, 2013, Time Plan:

Week 1 2 3 4 5 6 7 8 9 10 11


Realisation

Evaluation

I’m going to focus just on the research & development in the first term of my design. Hopefully, I

manage to get all the research, sketches and ideas completed by the end of term to allow me to

begin Realisation in the first term back next year. I will evaluate the progress I have made on my

project towards the end of the term.

Term 4, 2013, Actual time use

Week

1 2 3 4 5 6 7 8 9 10 11


Realisation

Evaluation

My project that I have selected will require a lot more time for research & development than I initially

expected at the start of term. I underestimated how long it would take to design a working product. I

have certainly made some progress however, as I have made some good sketches and conducted

some effective Research. Through evaluating my product, I have realised there are many different

parts that require further research before Realisation can begin.


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Term 1, 2014, Time Plan

Week

1 2 3 4 5 6 7 8 9 10 11


Realisation

Evaluation

I aim to have researched all the materials and processes for my design by the end of week 8. At this

stage I also aim to be close to finishing the development stages of my design, such as understanding

how it functions, and what ergonomic data is most applicable. If both the research and idea

development are completed, then I’ll be able to start the realisation in week 9. This will allow me to

begin constructing my product before next term, which will be important to avoid a rush towards the

final submission of the project.

Term 1, 2014, Actual Time Use

Week

1 2 3 4 5 6 7 8 9 10 11


Realisation

Evaluation

I was absent from school in the first two weeks due to my knee reconstruction and illness. When I

returned in week 3, I caught up on the class work and assignments that I had missed. During weeks 5

and 6, I realised that the path I was heading down with my MDP, wouldn’t have had sufficient

differentiation from similar products already on the market. This led to a major change in the design,

which allows for any earphones to be used with the product. The rest of the term consisted of

designing a retracting mechanism that functions properly.


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Week

1 2 3 4 5 6 7 8 9


Realisation

Evaluation

I aim to have completed most of the idea development by the end of week 6. I’ll be able to take in

some parts of the design before that, such as the inner case. This will enable Albury Precision

Engineering to begin manufacturing some of my design by around week 5, this will leave them with

plenty of time to manufacture the product, as well as some time for me to finalise the design, such as

soldering wires together. I aim to have the product completed by the end of this term, this will enable

me to evaluate the project and complete the folio in the final few weeks next term.


Week

1 2 3 4 5 6 7 8 9


Realisation

Evaluation

Once again, I was mistaken by how long it would take to design the product, and decide which

materials, mechanisms and processes would be most efficient. I’ve still made a fair bit of progress

however, and I should be able to go to APE in the holidays and talk to them about developing the

inner case. Next term a few more parts still require designing such as a case that covers the wires

from the conductive pathway, and a cover over the male audio port. In weeks 4 and 5, I had to find

another material to use as the conductive rings as I was unable to solder to aluminium.


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Week

1 2 3 4 5 6


Realisation

Evaluation

I must ensure that I complete the final designs of the final pieces, such as the cover that goes over the

male audio port and a case or hook to secure the earbuds when they are not in use. When this is

completed I can take these final pieces to Albury Precision Engineering for them to manufacture

these final pieces. I will do the final evaluation of my product in the last few weeks before submission.


Week

1 2 3 4 5 6


Realisation

Evaluation

The final parts that I had to design proved tricky to execute the dimensions and shape correctly, thus

it took me another week to finish the research and development stage. Realisation was initially held

back because of the excessive time that research & development took. Once I got my designs to

Albury Precision Engineering, it took them longer than I expected to manufacture my designs, as I

only received them back very late in week 5. In week 2, I realised that I wouldn’t have sufficient time

to design a clear case that would protect and secure the earbuds when they are not in use. In the last

few three weeks before submission, I completed the final evaluation and the final stages of my folio.


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Action Plan

Term 4, 2013, Week 1

To understand what a MDP needs to have to be successful.

Look at MDPs from previous years for ideas

Begin looking for a situation that could be fixed or made easier. I will look for this

situation by going about my day to day lifestyle and considering if any factors could be

improved.

I have grasped the fact that the MDP needs to be new and innovative from looking at previous

designs and seeing what scored well. A few situations have been identified, for example a device that

determines how much charge a battery still has.


Continue looking at previous MDP designs

Continue looking for a situation that could be improved, maybe consider asking others

to discover more situations, and then hopefully select one

A few more situations have been found, such as an easier mechanism to start a lawnmower, or a

doona cover that secures the doona at each corner. However, I am pretty confident that I will design

something to avoid earphones always getting tangled.


Look at any existing designs that stop your earphones getting tangled.

Begin thinking of possible designs to stop your earphones getting tangled.

Produce some sketches of any ideas

There are quite a few existing designs ranging from objects you can wrap your earphones around to

earphone cords that are resistant to each other and therefore don’t get tangled. Initial sketches have

begun however nothing substantial has yet been created.


Continue thinking and getting ideas down on paper, focusing on creating something

different and innovative.

Look at further existing designs to help generate ideas.

I believe I’m going to make an iPhone case that that has retractable earphones to protect them from

getting tangled and damaged. There are a few cases already designed, thus mine will be different by

allowing a wide range of earphones to be used with it.


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Look at other retractable devices to understand how the mechanism works.

Find any other iPhone accessories that could be added to the iPhone case.

I looked on the internet for any other retractable devices and found a couple. I also looked for some

iPhone accessories that I could incorporate into my design, however, most of them would be

inappropriate for my design. I could possibly include a wallet or a compartment that holds money

and cards.


Go searching for some cheap retractable devices in local stores that I could then pull

apart to understand how the mechanism works

Further my sketches, ruling out poorer designs

I have furthered a few of my sketches, and removed the poor or unrealistic ideas from the selection.

However I haven’t been able to get down the street and look for any retractable devices to analyse.


Go searching for some cheap retractable devices in local stores that I could then pull

apart to understand how the mechanism works

Complete the folio and PowerPoint presentation that is due on Monday next week.

Majority of time will be spent making sure the folio is completed to a high standard.

I managed to find a cheap retractable device at Officeworks. It even has a see through case that

allows me to understand the mechanism without pulling it to pieces. The folio and PowerPoint

presentation have been completed and rehearsed.


Recite PowerPoint presentation so it can be confidently presented to the class.

Investigate how the retractable device from ‘Officeworks’ operates. Consider ways to

incorporate this idea into my design.

I recited my PowerPoint a significant amount of times, allowing me to be confident in front of the

class and remember the words. I didn’t do any work with my project as we were presenting

PowerPoints all week.


Investigate how the retractable device from Officeworks operates.

Sketch any ideas, using a possible solution similar to the mechanism of the retractable

device from Officeworks uses.

I understand how the mechanism works, but I’m not completely sure how to incorporate it into my

design, and whether it is actually possible. Only limited sketching has been completed.


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Term 4, 2013, Week 10

Find out how to incorporate a similar retracting mechanism into my design.

Look for any other mechanisms that may be more suitable.

It will be difficult to incorporate a similar design and still allow for the earphones to be connected to

the phone. I haven’t yet figured out how I will achieve this.

Term 4, 2013, Week 11

Continue trying to create a functional design.

Get a computer designing program from my teacher so I am able to learn how to use it

over the Christmas holidays.

As this was just a two day week, in the last week of the year, very little work was completed. My

teacher suggested that the computer designing program, Creo Elements Schools Edition would be

most suitable, so I have taken a disk home to install it on my home computer to allow for further

progress at home.

Christmas Holidays

Install Creo Elements onto my home computer. Then learn how to use some of the

different tools

Start designing the retracting mechanism on the program

I’m afraid over the Christmas holidays I didn’t manage to install Creo Elements. However I did get a

few sketches down as ideas to incorporate the retractable mechanism.

Term 1, 2014, Week 1 & 2

I’m going to have a knee reconstruction the day before school goes back, so I won’t be

able to attend school for a week or two. If I’m feeling up to it, I could get some sketches

down of ideas to further develop the retracting mechanism.

Unfortunately, at the same time of the operation I also got glandular fever. Therefore I was mentally

and physically drained, leading to no work being completed over these two tough weeks.


Return to school, and catch up on any classwork and assignments I’ve missed.

Talk to the teacher about how to install the Creo Elements onto my home laptop.

I’ve caught up on the work that I missed, and collected the assignment sheets. Although it took a

while, by the end of the week Creo Elements has successfully been installed onto my home laptop.


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Learn how to use Creo Elements by completing a simple exercise that explains the basic

tools that I need to understand to operate the program.

Begin constructing my design on Creo using measurements taken from my earphones

and phone, and then estimating a suitable size for the retracting part of my product

I completed the exercise quite easily with it only taking a double period. I also managed to construct

my design on Creo, then printed it out made of plastic from the 3D printer, however when winded up

it puts too much force on a particular piece causing it to break. This problem is yet to be sorted.


Correct the problem that causes the part to break. To do this I will have to alter my

design and print off another prototype.

Check to see if the earphones smoothly slide in and out of the design.

The problem was fixed, simply by enlarging the part that broke. However, to make my product using

an automatic retracting system powered by a spring, I will be unable to include the ability to change

the earphones being used with the product thus differentiating it from already existing products.

Therefore, I feel that I need to explore other ideas to ensure my product is innovative.


Brainstorm other ideas that could be an effective mechanism to allow the use of a

variety of earphones.

If a good idea is created, begin designing it on Creo.

Go and purchase both a male and female audio jack from ‘Jaycar Electronics’.

A few ideas were pondered before I tested with my old prototype how it would work by simply

winding the earphones up by rotating the inner case using your finger. Surprisingly it was a lot faster

than what I expected. This simple design may just be what could work most effectively. I bought two

lots of both male and female audio jacks from ‘Jaycar Electronics’.

By having the mechanism powered by a spring, there isn’t enough room for me

incorporate a female audio port, which allows for different earphones to be used.

Therefore, I’ve had to abandon this design idea as my final product wouldn’t be

original, as it would be too similar to existing designs. I need to consider another

mechanism that allows a variety of earphones to be used.


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Design the retracting mechanism using the idea that it could just be rotated using your

finger. Include a place inside the inner case for the female audio port to sit, which will

allow for the male audio jack to be easily inserted.

I managed to design the case so that it can just be winded up easily using a finger. Initially it was just

flat and your finger would occasionally slide off, towards the end of the week I incorporated a little

circle that holds the finger in position allowing for it to be rotated even easier. However, it is difficult

to plug and unplug earphones from the female audio port. This will need to be made easier.


Slightly alter the design to allow for the earphones to be easily plugged into the female

audio port.

Get some significant work done on the Case Study due Monday next week, this will take

most of my time this week.

I have altered the design of the inside case, making the walls slightly thinner and curved, this

combined with removing a curved area of the roof of the case allows for fingers to have more room

to push the earphones into the female audio jack. The case study of the innovation was completed

and handed in on time.


Begin making some progress on the folio submission due Monday week 11

Try to design the actual case that protects the phone on Creo

I struggled with designing the case on Creo, as it was difficult to get measurements correct. Some

progress was made on the folio, however not as much as I would’ve liked.

Term 1, 2014, Week 10

Focus completely on the folio submission due Monday next week, as there is a fair bit of

work in it that will require a significant amount of time.

I managed to complete the folio to a standard that I’m happy with, although it was a bit of a rush,

it’s now finished. I will hand it in on time on Monday.

Term 1, 2014, Week 11

Hand in the folio submission Monday morning.

Try again in designing the case that protects the phone using measurements taken from

my iPhone.

I handed in the folio submission on time. I began to design the iPhone case, making more progress

than I had previously. Over the holidays I will need to focus on getting the measurements correct and

putting in all the holes for tools such as the camera and the volume buttons.


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School Holidays

Come in to school in week 1 of the holidays on Wednesday and Thursday to work on

designing the phone case. Focusing on getting the measurements accurate so the phone

will fit and the holes such as camera and volume buttons are in the right spot.

I designed the case and it fits onto my phone with the holes in appropriate positions, however it was

very difficult to get the phone into the case and out of the case. Therefore I tweaked the design, so

the case now comes apart into two parts: an upper and lower part. This should allow for the phone to

simply slide into the case.


Work on the new design idea with having the case in two different pieces. Print off a

prototype case to check how the design fits onto the phone.

Begin incorporating into the phone case a shell that the inner case sits in.

The new prototype with the two parts fits onto the phone reasonably well, however the lower part

had a few incorrect measurements not allowing it to fit into the upper case perfectly. No time was

spent on incorporating a shell for the inner case into it.


Redesign the lower part of the case so that it fits into the upper case smoothly.

Begin incorporating into the phone case a shell that the inner case sits in.

I’ve successfully redesigned and printed the lower part of the case and it now fits nicely into the

upper half of the case. I’ve designed a prototype that has the shell for the inner case to sit in. It also

has the slots for the conductive pathways that are required for the connection between the

earphones and the phone.


Print the iPhone case prototype with the shell for the inner case and the slots for the

conductive rings.

Cut two aluminium rings and a smaller circle of diameter 6cm on the metal lathe to put into

the phone case to be used as conductive pathways.

Use alkaline glue to glue these rings into the prototype that the conductive rings go into.

The prototype printed successfully. I managed to cut out the two aluminium rings and they’ve been

glued firmly into position in the iPhone case prototype. With the smaller circle, I used brass because it

will allow me to compare the two materials for future use.

I’ve had to split the iPhone case into two parts: an upper and a lower part. This

should allow for the phone to simply slide into the case. It is also the only way that

the male audio port will slide into the phone, once the product is complete.


19


Insert brass screws into the inner case to act as temporary points of connection with the

pathway, so that I can determine whether the design will successfully play music.

Solder wires from the female audio jack to the brass screws in the inner case. I must also

solder wires connecting the conductive pathway to the male port.

Look for alternatives that could be used instead of the brass screws. Perhaps slot car brushes

could be used to provide a stronger and more fluent connection with the pathway.

I’ve got the screws in place and I’ve soldered all the wires into the correct position, although I was

unable to solder to the aluminium rings, so I was forced to just wrap the wire around them. When I

plugged my earphones in and played music through my phone, the music only played quality music

when I held the inner case in a certain position on the conductive pathway. I’ve been to ‘The Hobby

Centre’ and have found some slot car brushes that I’ll try to incorporate to improve the connection.


Brainstorm ideas surrounding how to incorporate the slot car brushes into the inner case

design.

Consider other products that could be used as a point of connection between the inner case

and the conductive pathway.

I was unable to think of any ways that could incorporate these particular slot car brushes. However,

I’ve researched on the internet and found that there are other slot car brushes that are made of

braided wire. Towards the end of the week I was able to return to the hobby centre and purchase a

pack of these different brushes.


Alter the design, to suit the new braided wire slot car brushes.

Begin gluing the brushes into place and soldering wires together in the inner case.

I’ve changed the design quite significantly to enable fluent connection. A pole now comes up through

the middle of the inner case from the phone case; this will allow me to secure the inner case in

position as I can put a nut on the end to tighten the connection. This means the point that the inner

case rotates on is no longer a pathway, forcing three pathways around this pole. I printed this design,

and it looks as if it will work, however the pole is too fragile, and broke almost instantly.

The design now has a pole that comes up through the middle of the inner case from

the phone case; this will allow for me to secure the inner case in position as I can

tighten a nut on the end of the screw to ensure the connection, the nut can then be

loosened when I need to roll the earphones back up. This means the point in the

centre of the inner case that was used as a point to rotate on is no longer a

pathway, forcing there to be three pathways around the pole.


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Consider ways to strengthen the pole; possibly increasing diameter, or simply using a

different material.

Print off the new design

I’ve put a circle that will enable a screw to come up through both cases, this will enable the nut to be

easily tightened and it will not break. I’ve printed off the new design, but I haven’t begun gluing in

the brushes or soldering the wires together.


Visit ‘Bunnings’ to find both a screw that is the correct diameter and length, and a nut that

will fit that screw.

Look for an alternate material to use for the conductive rings as I was unable to solder to the

aluminium rings using the school soldering irons.

Begin soldering wires connecting the female audio port and the brushes.

I’ve been to ‘Bunnings’ and purchased a ‘wing’ nut as well as a ‘hexagonal’ nut both of 4mm

diameter. The ‘wing’ nut makes it easy to tighten and loosen the case which is important; however It

may get in the way. At school I have found some brass shim, which I am yet to cut out the rings from.

No soldering has been completed this week.


Cut out the three conductive rings from the brass shim.

Solder wires connecting the female audio port and the brushes.

Begin working on the ‘researching, explaining and evaluating impacts’ design and technology

assignment.

Purchase an extra male and female audio port from ‘Jaycar Electronics’ as the others are

soldered to other prototypes.

I have cut out all the rings from the brass shim, however they’re not in very good quality, the rings

are weak and the edges aren’t completely round. This is okay for the prototype, but I’ll have to get

the rings machined for the final design. I was still unable to do any soldering, however I did complete

the first question in the assignment and purchase both the audio ports from ‘Jaycar Electronics’.


21

School Holidays

Come into school on Monday and Tuesday from 9-4 of the second week of the holidays to

work on my project.

Solder wires connecting the female audio port to the brushes on the bottom of the inner

case.

Visit APE again and give them the final designs for the inner case.

Complete the design and technology assignment on ‘researching, explaining and evaluating

impacts’.

I came into school, and spent most of the time trying to solder the wires together appropriately, this

proved a difficult task with the faulty school soldering irons and the lack of room there was for the

soldering iron head. The heat from the soldering iron caused part of the plastic to melt, and in the

end I was unable to solder the wires from the female audio port to the brushes. On the Tuesday, I

spent time re-designing the inner case into two parts, which will enable much easier soldering and

then these two parts can just be screwed or glued together. Tuesday afternoon I visited APE and they

are going to begin manufacturing the inner case for me.

.


Design a little cover to sit over the male audio port once the wires have been soldered into

position. It will need to be sleek, and suit the rest of the design.

Design another small, thin lid that covers where the wires have been soldered onto the brass

conductive rings.

Consider ways to secure the earphones when they are not in use. Could include some sort of

mould with a clear case that covers them or a hook to hold them down.

I’ve designed a little cover to conceal the male audio port. However, I haven’t been able to make the

other lid, and I struggled with thinking of ways to hold the earphones in position.


Consider ways to secure the earphones to the case when they are not in use. Could include

some sort of mould with a clear case that covers them or a hook to hold them down.

Design a thin lid that covers the wires running from the conductive pathway to the male

audio port.

I’ve decided that there is not enough time to design a clear case that is on a hinge that protects the

earphones when they are not in use. I have fiddled with a few things on Creo trying to design a hook;

but I have been unsuccessful so far. However, I was able to design the thin lid that covers the wires

running from the conductive pathway; this lid will go on after they’ve been soldered together.

Due to being unable to access inside the inner case with the soldering iron, It’s

forced me to have to re-design the inner case into two parts, basically just

taking the top of the inner case off, this will allow me to solder easily, then I can

simply screw it together afterwards


22


Design a mould or hook that secures the earphones to the case when they are not in use.

Print off the final design of the whole case. (the upper and lower parts of the phone case,

the lid that covers the wires and the lid that goes over the male audio port.)

Design a little logo that can be incorporated into a corner of the case, this design will also be

used throughout the folio and will provide some personalization for my project.

Approach Albury Precision Engineering again to check up on the construction of the inner

case, as well as giving them the final phone case design to manufacture.

I have finally selected a hook shaped part that secures the earphones when they are not in use. I’ve

printed off each part and I’m happy with how it looks. Through making a number of thumbnail

sketches I designed a symbol that consists of my initials and I will use it as my logo. I have

approached APE and disappointingly, they still haven’t begun the production of my inner case,

however I gave them the rest of the designs and they will get it done for me.


This is the first week of my HSC trials. So pretty much all of my time is going to be spent on

my exams.

Towards the end of the week, I will go to APE to check up on the progress of the

manufacturing of my design.

On Friday I went to APE to check on the progress of my design. They have successfully completed the

inner case to a really high quality. I must return early next week for the rest of my design.


This is the second week of my HSC trials. On Tuesday, after my final exam I must revisit APE

to hopefully collect more if not all of the pieces of my design.

I must take the manufactured inner case to ‘Tele-Fix’ to get them solder wires from the

female audio port to the brushes.

After the wires are in place. I need to screw the inner case together into one piece. I will

have to consult APE, to ensure that I do this correctly.

I’ve been to APE, and unfortunately it wasn’t until Saturday morning that I could collect the main

iPhone case part.


This is the final week of the project, everything must be submitted by 3:30 on Thursday. I

must ensure that every component of my folio is complete and to a high standard. I must

also complete the final evaluations of my product.

I’ve managed to get all of the folio, my product and my props completed to a high quality just in time

There is insufficient time left for me to design a clear case that is on a hinge

that protects the earbuds when they are not in use, therefore I must focus on

designing a basic hook or something to hold them down.


23

Finance Plan My parents and I have come to the conclusion that they will fund everything for my major design

project within reason. They have given me a budget of $200, if the costs exceed this, then it is up to

me to fund. However, if my project is a success, and I do decide to go into mass production of my

design then it’s up to me to fund that prospect. The majority of costs will occur towards the end of

the design, when it comes time to manufacture the final design.

Plan:

What

Where Price ($) When

Retractable device

Officeworks / Spotlight 5 Midway through Term 4, 2013

4 Audio jacks (both male and female)

Jaycar Electronics 20 Towards the end of Term 1, 2014

Printing and plastic used in 3D printer

School Nil - Price included in my school contribution

Term 1, 2014 onwards

Slot car brushes

The hobby centre 10 Midway through Term 2, 2014

Manufacturing of product

Albury Precision Engineering

100 Towards the end of Term 2, 2014

Printing and binding of folio

Officeworks / The Printer Wizards

50 Week 5 or 6 of Term 3

Total: $185

Actual Costs:

What

Where Price ($) When

Retractable device

Officeworks 8 Week 7, Term 4, 2013

6 Audio jacks (both male and female)

Jaycar Electronics 9 $6 in week 6, Term 1, $3 in week 9, Term 2

Printing and plastic used in 3D printer

School Nil – Price included in my school contribution

Term 1, 2014 onwards

Slot car brushes

The hobby centre 16 Week 4 and 5, Term 2, 2014

Manufacturing of product


Nil Midway through Term 3, 2014

Printing and binding of folio

Mothers work, then Officeworks

75 Week 6, Term 3

Total: $108

I was incredibly lucky as ‘Albury Precision Engineering’ manufactured my product free of charge, it

took them a number of hours to construct my design and this would’ve easily totalled $1000+. I also

unexpectedly had to return to ‘Jaycar Electronics’ and purchase another male and female audio port.

The printing and binding of the folio was a little more expensive than I had expected, however it’s

well worth it for the quality finish.


24

PROJECT

DEVELOPMENT

AND

REALISATION

http://pmdstudios.com/wp-content/uploads/2013/07/ideaguy.jpg


25

Research

Research of Existing Designs

1.

Sleek wooden design

that is light, reliable

and durable.

Ear Buds neatly rest on the

edge of the wooden frame,

giving them somewhere to sit

rather than just hang.

Cord wraps neatly around the

wooden frame which protects

it from getting damaged.

Earphone buds, cannot get

back through the wooden

frame as the hole is too small.

This keeps them from

unravelling.


26

2.

Earphones retract into the

Phone case. Keeping the cord

untangled and protected.

The case still does

its primary function

of protecting the

phone.

Earphone cord and retracting

mechanism is hidden

somewhere in the case.

Case opens from

the back. So that

phone can be put in

and taken out.


27

3. *THIS PRODUCT IS JUST A MODEL*

Clear case that

protects earphones,

opens to allow

earphones to come

out, and then closes

again.

Earphone case comes apart

from the phone case if the

owner doesn’t want the

earphones attached.

Sleek, neat looking

design. However it may

be too bulky for the

everyday phone use.

Buttons to use as controls

instead of having to use

the screen.


28

4.

Plug that goes into

phone retracts into the

round frame as well.

Earphones

retract into the

round frame.

However they

just dangle

there not being

secured by

anything.

Neat round design

that protects the cords

from damage when

not in use.

A carabiner that

allows for the

earphones to be

attached to things.


29

5. *THIS PRODUCT IS JUST A MODEL*

Volume

controls

Earbuds are attached firmly by

magnets when they are

retracted back into the case.

Storage space for

the earphone cord

when not in use. Wide cord to avoid

tangling, however

this would take up

more space,

leading to a bulkier

design.

Audio connection

moulded into the case,

this allows for the

earphones to connect

to the phone.


30

Research from Areas of Investigation

Materials:

With my design I could make the case out of a few different options. It could be made from ABS

plastic from the 3D printer, Aluminium, Acetal, or from polyethylene.

Acrylonitrile Butadiene Styrene (ABS) Plastic:

ABS is a terpolymer of acrylonitrile, butadiene and styrene.

Acrylonitrile butadiene styrene materials can be processed by any of

the standard thermoplastic processing methods such as by a 3D

printer which adds a series layers or a router which takes layers away.

ABS possesses outstanding impact strength and high mechanical

strength, which makes it so suitable for tough consumer products.

Additionally, ABS has good dimensional stability and electrical insulating

properties. Commonly used for a range of products such as:

Telephone bodies

Safety Helmets

Piping & Furniture

Car components & TV Casings

Overall, ABS plastic is a reasonably good material to use, however some of the finishes aren’t perfectly accurate especially with the school’s 3D printer. But, the ABS plastic is more than sufficient for the working prototypes.

Aluminium:

The element aluminium is the third most plentiful element in the earth’s crust, comprising 8% of the

planet’s soil and rocks. Aluminum manufacture is accomplished in two phases: the Bayer process of

refining the bauxite ore to obtain aluminum oxide, and the Hall-Heroult process of smelting the

aluminum oxide to release pure aluminium. Aluminium can be manufactured

into a range of products as it is so versatile, and it is easily and economically

recycled into new products.

Aluminium has a large number of fantastic in-service properties, such as:

Lightweight & strong as well as being Nonmagnetic & Nontoxic

Conducts heat and electricity and reflects heat and light.

Retains its strength under extreme cold without becoming brittle.

Has a barrier against corrosion.

These incredible characteristics of aluminium lead to it being a material that is

often used to produce a lot of products such as cans and having a major role in

the automotive industry with tools such as pistons. Aluminium looks as if it could

be a very suitable option for my design if it is aesthetically pleasing.


31

Acetal:

Acetal is a thermoplastic produced by the addition polymerization of an aldehyde through the

carbonyl function. Acetal is effectively manufactured by using conventional injection moulding and

extrusion techniques. The main area of application for acetal is industrial and mechanical products.

Acetal is a plastic that often competes with nylons for many of the

same applications. This is because of its exceptional in-service

properties:

Good fatigue life

Low moisture sensitivity

High resistance to solvents and chemicals

Good electrical properties

These properties lead to acetal resins being

amongst the strongest and stiffest of all

thermoplastics. Ultimately, with these

characteristics, acetal has to be considered as an

option to manufacture my design.

Polyethylene:

Polyethylene is derived from either modifying natural gas or from the catalytic cracking of crude oil

into gasoline. Manufacturing processes are usually categorized into ‘high pressure’ and ‘low

pressure’ operation. High pressure is generally recognised as producing conventional low density

polyethylene while low pressure makes high density. By using the appropriate pressure of

manufacturing a wide range of products can be produced. Polyethylene

could be a suitable material for the construction of the phone case. It is

commonly used in manufacturing because of its quality manufacturing

properties.

Polyethylene has very good In-Service properties which would lead to it

being effective as the material of the phone case. Those properties are:

High resistance to abrasion.

Good flexibility

Light weight

Robustness

This has led to their widespread use in applications such

as transportation of slurries and mine tailings. As well as

their use in a wide array of pipes ranging from being

used to make large water pipes and also being used in

far smaller pipes.

http://www.google.com.au/url?sa=i&rct=j&q=manufacturing+acetal+plastic&source=images&cd=&cad=rja&uact=8&docid=WSqPy1Bj4rRlNM&tbnid=XYRghHCO99W7WM:&ved=0CAUQjRw&url=http://www.connecticutplastics.com/capabilities-and-parts/materials/delrin_acetal/parts-photos/&ei=nfXzU5naEY2D8gXhg4CQBg&bvm=bv.73373277,d.c2E&psig=AFQjCNFdkSdrOR9cLesblhc6TDy6BIfqtw&ust=1408583446392797

http://www.injectionmouldtooling.com/photo/pl409298-custom_abs_or_pvc_acetal_overmolding_injection_molding_plastic_injection_molded_parts.jpg


32

Creo Elements & 3D Printer:

Learning how to use Creo Elements and the 3D printer is absolutely crucial to the design of my

product. Knowledge of how to use these devices will allow me to design and construct full working

prototypes which will help to determine the most efficient design.

To begin, my teacher gave me a targeted training tutorial on Creo

that demonstrates how to make ‘Extrusions’. This exercise taught

me the basics of how to use Creo and then over the course of

designing my prototypes I gradually became more experienced and

confident. I have since installed Creo Elements on my home laptop

which allows me to use it at home as well as just at school, thus

increasing my access and involvement with Creo.

Through my gradual improvement, I was able to

design very complex designs such as my upper case

design. This took a significant amount of time to

learn all the tools required to ensure that the design

if fully functional and accurately measured for

correct size and shape.

The 3D printer automatically prints off all my designs that I create on

Creo. My teacher showed me the basics of how to turn the printer on

and how initialise the program and begin printing. Over the wide range

of prototypes I created, I became adept at fixing minor problems that I

encountered in the set-up of the printer and I learnt how to change the

plastic used by the printer. Through my gradual improvement in designs

I was able to learn how to use Creo and the 3D printer to a higher level.

Safety:

The design must not be dangerous for those who use it or others.

Through my prototypes I have been able to check each design to ensure

that they are all completely safe. It has shown me that all the sides

need to be slightly curved; the removal of the edge makes it softer on

the hands of the user.

The prototypes have allowed me to change the design to a design that

is powered by the users finger. This means that the speed and direction

of the winding up is controlled by the user. This reduces the possibility

for any injuries surrounding fingers, or hair getting caught in the inner

case, if it were to retract automatically.

Curved edges for

improved comfort

and safety


33

Security:

It is very important for the design to protect the earphones whilst

both in use and not in use. Through the prototypes I was able to

decide which size, shape and mechanism is most appropriate to

secure the earphones into the correct position.

The security can be easily tested with these full-sized prototypes.

The working prototypes allow me to plug my earphones into and

the female port and then retract the earphones back up into the

case. This demonstrates that the retracting of the design is fluent

and doesn’t damage the earphones. The prototypes allowed me to

come to a final design that doesn’t put too much tension on the

cord when winding them up and allows the earphones to be

stored nicely when they are not in use.

Function:

The development of my prototypes has been crucial to determine which mechanism retracts the

most efficiently. Initially I was going to power the mechanism using a spring. When I incorporated

this idea into a prototype, I realised that it wasn’t going to work as it caused to much force on the

case leading it to snapping.

I changed the mechanism to being winded up simply by using a finger to rotate the case around the

spindle and wrap the earphones up into position. The prototypes allowed me to confirm that this

idea for the mechanism was successful and that it would work. Without the prototypes I would’ve

been unable to determine whether my design is fully functional.

Durability:

The prototypes have determined which design is the most reliable and durable. Originally, I was

going to have the retractable mechanism powered by a spring, however, the force caused by the

spring in order to retract the earphones lead to a mandatory part of the design to snap. The

prototype proved that this design was going to be weak, and that there will be many problems

involving the spring.

The mechanism that is powered by the user’s finger has proven successful through the prototypes.

The range of prototypes have demonstrated which designs or areas of a design are weak and require

improved strength.

I conducted research on the internet determining the strength characteristics of aluminium, nylon

and PET.

Aluminium – High strength, Low weight, Crash Absorbent, Rust Resistant, very versatile.

Overall, aluminium is a strong material that would be durable enough for my product.

Nylon – High mechanical strength and superior resistance to wear and organic chemicals

which is very important for phone cases as the must endure the daily impacts.

ABS Plastic – Outstanding impact strength and high mechanical strength, which makes it

suitable for tough consumer products; such as my phone case.


34

Test – Clay Modelling

Aim:

To determine which case design feels most comfortable whilst being used by shaping clay into the

shape of the iPhone Case.

Equipment:

- Craft clay

- Newspaper

- Glad Wrap

Method:

1. Lay down newspaper on a desk, table or bench.

2. Remove clay from packet

3. Begin shaping the clay into a similar shape to an iPhone case

4. Experiment with different edges, curves and thickness to examine which shape is most

effective.

5. Create a couple different designs and leave them to go hard.


35

6. Wrap excess clay up in glad wrap to prevent it from going hard.

Results:

With the clay that I had I managed to make two designs. The first design is very basic, aiming to only

take up the space that needed to be taken up. I have just included the retractable mechanism for the

earphones and the area for the earphone buds themselves. The second design is a little more

creative. I have added a similar sized area on the opposite side to that of the earphone buds. I have

also made all the edges more rounded and smooth. This design is more aesthetically pleasing,

however it does consume more space which could hinder the design whilst in use.

Conclusion:

This test has proven to me that most designs feel comfortable, as the hand adjusts to the shape, just

as long as there are no sharp edges. Both of these cases are easy to hold, however I prefer the

second design as it is a little more complex than the basic first design.


36

Test – Development of Prototype Inner Cases

Aim:

To understand how the retractable mechanism is going to work, and to prove whether or not my

designs are successful.

Method:

1. Learn how to use Creo Elements and the 3D Printer

2. Design a variety of different methods for retractable mechanisms on Creo.

3. Print these designs off using the 3D printer.


37

4. Clear out excess plastic from the prints

5. Examine the designs to understand which option is the most efficient and effective.

6. Use the design as it would be used to determine its functionality, durability and security

Results:

My original design where the retracting mechanism was going to be automatic as it was powered by

a spring, proved to be unsuccessful as the durability of the design was disappointing. This led to a

change in the main mechanism, changing it to being powered by effortlessly winding the earphone

cord up with your finger. The prototypes I designed gradually proved that this design would be

functional, reliable and durable for the intended use of protecting earphones.

Conclusion:

The prototypes have easily allowed me to rule out the poor options and decide on a final design that

will be functional, reliable and durable whilst securing the earphones at all times.


38

Test – Conductive Rings

Aim:

To determine which material would be most appropriate as the conductive rings. The test will

conclude which material is the most conductive as well as which material is the most reliable and

durable for the function it will be used for. The material must be easy to solder to and highly

conductive.

Method:

1. Make 2 aluminium rings in the metal lathe and a brass circle to use as the conductive points.

2. Draw and cut out 2 rings from brass shim to compare to the other materials.


39

3. Glue the rings into the two different prototypes

4. Solder the wires to both of the audio ports

5. Test the strength of the connection by plugging in the earphones and playing music from the

phone through the product.

Results:

The aluminium rings and the brass circle were successfully made on the metal lathe. They are both

very strong and would definitely be durable enough for their required function. However, I was

unable to solder to the aluminium rings, forcing me to just wrap the wire around the ring instead.

The rings cut out of the brass shim were very difficult to get accurate and it was clear that they

weren’t going to be durable enough. I also struggled to solder to the brass shim.

Conclusion:

Aluminium won’t be used for the conductive rings as I was unable to solder to it. The brass shim

won’t be used simply because it lacks durability and doesn’t look professional. Ultimately, the brass

rings that were machined in the lathe is the only material that is durable and reliable for its intended

use and that I’m able to solder to. Therefore, I will use machined brass rings in any future prototypes

and the final product.

Aluminium

rings

Brass circle

that acts as

point of

connection

and as a point

for rotation

Rings cut

out of

brass shim

Brass circle

machined on

lathe from a

solid cylinder

of brass


40

Test –Final Design Material Selection

Aim:

To determine which material between Acetal and Polyethylene would be most appropriate for

making the design.

Method:

1. Test to see whether the inner case can be manufactured out of the black Polyethylene.

2. Test to see whether the phone case can be manufactured out of the black Polyethylene.

Problems arose involving parting off the design

leading to unsightly marks and stubs. This led to many

copies having to be made before one was successful.

The Polyethylene

frayed significantly

from the machining

The surface was rough

after machining, which

wouldn’t be good for the

phone.


41

3. Test to see whether the phone case can be manufactured out of the white plastic Acetal.

Results:

The plastic polyethylene proved to be too fragile to be

delicately manufactured into the phone case; however, the

inner case was able to be made in polyethylene even with the

few issues that arose. The phone case was made out of the

plastic Acetal. It didn’t leave as many burrs and rough edges,

and was clearly the best option for the phone case.

Conclusion:

Overall, Acetal proved itself to be a more durable and reliable

material in the production process. It was much easier to

manufacture and left the surfaces much smoother and neater.

Therefore, Acetal was used for the final design of the phone

case. Polyethylene is sufficient for the inner case as it isn’t as

difficult to manufacture, the final inner case design also looks

aesthetically pleasing, reliable and durable.

The plastic Acetal proved to be much stronger and

easier to manufacture than the Polyethylene.


42

Application of Conclusions

Application of Conclusion from test ‘Clay Modelling’:

I learned from the test that it doesn’t matter the shape of the case that much, as long as there are

no sharp edges. It is important that the case is aesthetically pleasing, such that it isn’t too plain yet

still being as light and small as possible as this is crucial to the function of the design. My designs are

mainly based around the second clay model I made.

Ultimately, the ‘Clay Modelling’ test has allowed me to design a case that fits comfortable in the

user’s hand. The case also takes up only the required amount of space, similar to that of the model.

The model allowed me to be confident that my design will be comfortable in use.

Application of Conclusion from test ‘Development of Prototype Inner Cases’:

The gradual change in prototypes has allowed me to continuously improve the design over a number

of stages until I approached my final design solution. The prototypes acted as a quick option for me

to test whether the design is functional, reliable, and durable and indeed whether it plays music. The

prototypes allowed me to have a visual representation of my designs as well as allowing me to be

confident in my design when I go to make the final copy.

These prototypes have been a main focus of my design process. They have allowed me to analyse all

the details of my design and prove that the design solution is capable of fulfilling the design brief.


43

Application of Conclusion from test ‘Conductive Rings’:

This test enabled to find out which material is the most conductive, durable, reliable and easy to

manufacture and solder to. The test showed that aluminium rings weren’t capable of being soldered

to, it also showed that cutting out rings from brass shim is too fragile. Brass rings that are machined

on the lathe are the only solution that is suitable for the task as conductive rings. This test enabled

me to be sure that solid brass rings are the right thing to use in the final design.

I implemented the success of the inner brass ring into all of the rings in the final design. This test

allowed me to determine a material that will be efficient, durable and reliable and be able to

confidently use it in my final solution.

Application of Conclusion from test ‘Final Design Material Selection’:

This test allowed me to decide whether polyethylene or Acetal would be the most appropriate

material to use in the production of my final design. It was an important test as it’s crucial that I

select the right material to ensure the properties of the

material are the most suitable for its intended use. The

test quickly showed me that polyethylene wouldn’t be

the preferred material for the phone case as it was hard

to manufacture and left lots of burrs and rough marks.

However, the polyethylene is suitable for the inner case

as it isn’t as hard to manufacture.

Through the test, I know that I’ve used materials that will

be durable, reliable and efficient for the intended use.

Ultimately, the test has allowed me to be sure that I’m

using the correct material for each part of the design.


44

Consideration of Design Factors

Function:

The function of the design is absolutely crucial. If it doesn’t function properly then the product will

be a failure. For the product to be successful in terms of function:

It must be able to protect the earphones from getting tangled and damaged when not in

use.

The cord must smoothly and easily retract back inside the inner case without any problems;

conversely, it must also smoothly slide out of the case without any problems.

The music needs to be at the exact same quality as if the earphones were directly plugged

into the phone.

The case must protect the phone itself from most damage.

For my product to be successful the functional aspects are key. Everything else is built around the

function; therefore if the product functions reliably and efficiently the product should be successful.

Ergonomics:

The ergonomics of the design are also very important. The design needs to suit the surroundings it

will be used in.

When not in use the product will most likely be in a pocket or bag. Therefore it must not be

too large which could be uncomfortable to carry in your pocket.

When in use, the design will most likely be in your hand, in this case, it must not be too large

that it requires two hands or too heavy that it puts unnecessary strain on the user.

It may also be used resting on a flat surface, the back of the case ideally should be flat to

ensure that the phone can sit somewhere without being insecure.

The dimensions have to very accurate, because if they are too small the case may not fit or the

earphones may not roll all the way up in the case. Size and shape is very important in these areas:

The case that holds the earphone cord must be large enough to accommodate most cords,

yet not being too large and wasting space.

The phone case that latches onto the phone must be very accurate to ensure that the phone

fits correctly, with very little room for movement.

The positions of all the holes for devices such as volume buttons, camera and the lock

button all need to be in the correct spot or otherwise they will not be able to be accessed.

Ergonomics is a major concern and needs to be analysed in depth to ensure sizes and shapes are

correct for all users.


45

Aesthetics:

The aesthetics of the design are what captures a customer’s eye; it’s what makes my product stand

out from the rest on the shelf. My design needs to look like it’s strong and built to last, whilst also

having an appealing and colourful paintjob. iPhone cases are often something an individual looks for

to customise their appearance and style. Therefore it is important for the design to be new and

innovative. If the design functioned perfectly and was the most well designed case ever, yet it looked

terrible, then it’s not going to be anywhere near as successful. This proves that the case must have a

new and aesthetically pleasing appearance that is different from its rivals.

Finance: Initially, the price isn’t that much of a concern because it won’t cost very much to design and

manufacture. However, if my product indeed proves successful, then after I graduate from high

school I may look to conduct wide-spread marketing and distribution of my product. In this case, the

financial costs involved in designing, manufacturing and marketing the product become quite

relevant. To compete with substitute goods my design will need to be produced using resources as

efficiently as possible. The components, processes and labour that go into the product combined

with the marketing need to be low enough so that I still make profit from the sales of my product.

Quality:

The level of quality is very important. My product aims to give earphones a longer lifetime as they

are delicate items that often break. The case needs to be able to sustain this for an acceptable

amount of time, all cases are designed to last for a long period of time, and my case is no different.

The case must be able to endure a significant amount of time protecting both the earphones and the

phone without breaking or malfunctioning.

The overall durability, reliability, precision and ease of operation need to be dependable for a

substantial amount of time. The consistency of quality becomes important if I go into mass

production of my product, if so, all copies must be of the same high quality as the original.

Obsolescence:

Designs gradually become obsolete as technology grows leading to improvements in software and

materials. My design needs to be able to accommodate for these changes in technology with a

simple, small alteration that allows for the product to become timeless. Problems caused by

improved technology for my product:

As technology improves new phones are always being released. My case needs to be able to

adapt to the new style of iPhone that comes out almost yearly. The case needs to be able to

change to suit the new style by simply altering the dimensions of the phone.

With improved technology, in the near future following the trend of wireless phones and

controllers, wireless earphones could be a new invention in time to come, and when they

become popular; my design will become completely obsolete as there is no cord to get

tangled.

Ultimately, obsolescence is an inevitable problem with the rapidly improving technology of this day

and age. However, by designing the design so that it is easily altered, the case should be able to stay

relevant and not become obsolete as quick.


46

Idea Generation

Overall Designs

1.

The two ends prevent the

earphones from sliding off.

Earphones

potentially

could untangle

as nothing is

holding them

in place.

Earphone cord

wraps neatly

around the strong

frame.

Reliable and durable

frame made from a strong

wood, metal or plastic.


47

2.

Lightweight

design that

looks fantastic,

however gives

minimal

protection. Position for earphones to

sit when not in use.

Retractable

earphone

mechanism

hidden inside

case.

Audio connection is moulded

into case, which allows for a

sleek, non bulky design.


48

3.

Little strap that holds

earphones down

when they are not

being used.

Retractable

earphone

mechanism

hidden on the

inside of the

leather case.

Can be removed

if earphones

aren’t needed.

Three pockets to store cards

and money in. Therefore

case is operating as a wallet

as well. Leather case that is flexible,

soft and aesthetically pleasing.


49

4.

Position for earphones

to sit when not in use.

Retractable

earphone

mechanism

hidden inside

case

Case comes apart

into two pieces to

allow for phone

to be easily put in

and removed.

Audio connection

moulded into case

to allow for a sleek,

non bulky design.

Heavyweight

and durable

case that

protects the

phone.

This design is my preferred appearance of the case, I will try and design the

final product so that it resembles this design.


50

Inner Case Designs

1. The initial design, where the retracting mechanism is powered by a spring

This design may have worked, however by using this design I wasn’t going to be able to

incorporate the ability to use different pairs of earphones with the product, therefore

this design had to be abandoned. The durability of the design was also at question.

With a few of the prototypes the tension caused by the spring caused pieces to break,

that problem could’ve been solved, but there are likely to be others involving the

spring.

Hole in case for wires

to run through.

Hole for pole to

come through

from bottom case. Gap to wedge

the spring into,

this enables the

inner case to

automatically

wind up.

Pole to go up through

inner case. Spring lodges

into it, enabling the case

to automatically wind up.

Hole for earphones to

come through.


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2. Design is altered so winded up by rotating with finger

This is my selected mechanism for the earphones to plug into and wrap around. It is very

simple to use, which will lead to less problems and better durability. With the use of

stronger materials and more accurate manufacturing, the system should only get

smoother.

Small hole for the little stub

on the inner case to rotate.

Hole for earphones

to come through.

Position to put

female audio jack.

Underneath in the centre,

there is a little stub

allowing for the inner case

to rotate more freely.

Position to keep fingers

from slipping when

winding up earphones.


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3. Design is progressed to allow for brushes and female audio port

Slot for female audio

jack to slide into

Slots for brushes to slide

through and glue onto

Finger groove

to enable

easier winding

Hole for screw

to come through

Hole for camera

Slots for conductive

rings to run on to

provide a connection

between the earphones

and the phone

Hole for earphones

to wind through


53

4. Design is split into two parts: an upper and a lower part

Finger groove to

enable easier winding

Gap for beam from the

bottom half of the

inner case to click into

Hole for screw

to come through

Slot for female audio

port to slide into

Beam for earphone

cord to wrap around

Slot for female

audio port

Slots for brushes to go

into and glue to each

side of the case.


54

Phone Case Designs

1. The One-Piece Clip on Case

Hole for

camera

Holes for the male audio

jack and the lock button

Hole for

volume

buttons

Thin extrusion to

secure the phone

in the case.

Hole to enable

iPhone charger to

be connected

The phone was really hard to get into this case, therefore it needs to be broken up

into two parts to allow the phone to easily slide into the case instead.


55

2. The Split Case

Hole for

camera

Hole for the lock button; hole

is chamfered on the other side

to allow easy access to button.

Thin extrusion to

secure the phone

in the case

Hole to enable

iPhone charger

to be connected

Slot cut out to

enable slot on lower

half case to fit in.

Slot that slides into the

upper case, which keeps

the case together


56

Final Phone Case Design

Slot that enables the

conductive pathways to

be soldered to the male

audio port

Slots allowing for

brass rings to be glued

in and act as

conductive pathways

Personal Logo

Earphone hook

and resting area

Hole to enable the

iPhone charger to

be connected

Slot that slides

into the upper

case, which holds

the case together.


57

Minor Parts:

Nut Cover

Hexagonal cut-out

to glue nut in

correct place

Leaver to make

tightening and

loosening easier

Wire Cover,

printed in the right

shape to just glue

over the wires

Male audio

jack cover

Rectangular hole

for the male audio

jack to fit in

Rectangular shape to help

guide into the right

position in the upper case


58

Identification and Justification of Ideas and Resources Resources Type Justification

Tools/ Machines Creo Elements I’m using the computer drawing program Creo because it allows me to design my drawings and then print copies off using the 3D printer. It also develops my designs transforming them into more professional drawings. I will be able to hand an engineering manufacturer my design on Creo and they should be able to just build it with the measurements I’ve provided through Creo.

3D Printer The 3D printer is a really important tool in the development of my project. It has allowed me to print off prototypes of each of my designs, this allows me to analyse with them instead of just imagining them in theory.

Soldering Iron Soldering irons are required for me to solder wires connecting the female audio port with the slot car brushes in the inner-case, they are also used in the phone case when I needed to connect the brass rings to the male audio jack.

Metal Lathe The metal lathe is used to produce the brass and aluminium rings that I need to have to test which material is most suitable to use as the conductive pathway.

Knowledge People Teachers The teachers at my school have been teaching the Design & Technology course for years. They have a range of knowledge and are only too willing to share it with us.


The engineers at Albury Precision Engineering are full of knowledge about how to design and create designs like mine. They knew which materials I should use for which parts of my design. I have also worked with them before in the Albury High School solar car team and I know that they are a capable company.

Friend that is confident with editing videos

I don’t know much about editing videos. Therefore I need a friend that has lots of experience with editing videos so that my video can be of a high quality.

Tele-Fix I only learnt how to solder at the start of this project. Therefore for the final design I’m going to go to Tele-Fix and ask them to do the soldering for me. They also have much better soldering irons and smaller wires which is important for the success of the design.

Information Internet The internet has a vast array of information that is at my fingertips. I must just ensure that the information is valid.


59

Text Books We have text books at school. They have some good information regarding the techniques used in Design and Technology.

Materials ABS plastic (Plastic from 3D printer)

ABS plastic is a strong, lightweight plastic yet it is still highly resilient to scratches and dints. It is important for my design because I can make prototypes using ABS plastic from the 3D printer. This plastic was only used for the production of the prototypes.

Aluminium Aluminium iPhone cases are hard and sturdy. A case made from aluminium protects the phone from shock damage if dropped. Aluminium cases also keep the phone from accumulating scratches and dings that occur normally within daily use.

Acetal Acetal is a valuable plastic that could be used to manufacture the phone case as it has good fatigue life, low moisture sensitivity, high resistance to solvents and chemicals and good electrical properties.

Polyethylene Polyethylene is a strong plastic that could also be used to manufacture the phone case as it has good in-service properties such as high resistance to abrasion, good flexibility, light weight and robustness

Methods Prototypes By making prototypes it allows me to understand which design is the most reliable, efficient and durable both when in use and not in use.

Clay Modelling Clay modelling allowed me to understand which shaped case was best accustomed to being held, and laying on a surface. It also allowed me to determine which design was most appealing.


60

Realisation of Design Solution Initially I had to design the case on ‘Creo Elements’, which is a computer assisted drawing program.

It took a significant amount of time but eventually my designs became more and more functional.


61

3D printed prototypes:

Secondly I had to print off these designs on the 3D printer. This will give me a wide range of

prototypes that I can use to determine the appropriate mechanism and design to address the design

brief.

Then with these prototypes I must decide which design is the most effective and efficient at solving

the situation.


62

Manufacturing:

When I selected the chosen design that I believe is the most effective solution to the problem I went

to ‘Albury Precision Engineering’. I asked them to manufacture my design, they made it out of

Polyethylene and Acetal which are much stronger plastics compared to the 3D printer.

Constructing the lower

half of the inner case –

It’s secured in a vice

just after drilling the

hole in the centre.

The upper half of the phone

case is secured in a vice whilst

extrusions are taken away.

The upper half of the

inner case, just before

it’s parted off. Polyethylene

Acetal


63

Soldering:

After I got the manufactured product back from ‘Albury Precision Engineering’, I had to solder the

wires together, I decided that rather than I do it like I did on my prototypes; I should take it to

professionals at ‘Tele-Fix’. They were able to quickly solder it together for me.

A wire was soldered to each

brush connecting them with

a different terminal in the

female audio port.

A wire was soldered to each

conductive ring connecting

them with a different terminal

on the male audio port.


64

Gluing:

Once the wires were solded into position, I was able to glue everything down so that there isn’t any

unwanted free movement.

Gluing the brushes down into

position, this will keep them secure

and limit the fraying as they rub on

the conductive pathways.

The brass rings just after

they’ve been glued into place

to act as the conductive rings.

Gluing the screw into position, this enables the

nut to be tightened without the screw spinning.


65

Gluing the male

audio port into

position against the

edge of the case.

Gluing the cover down

that protects the male

audio port and the

surrounding wires.


66

After the wire cover

has been glued

down, it

successfully

conceals the wires.

Gluing the wire

cover down

The earbud

holder is glued

into position.

Gluing the earbud

holder into position.


67

WORKING DRAWINGS

1. The Upper Half of the Phone Case


68

2. The lower half of the Phone case


69

3. The Upper Half of the Inner Case


70

4. The Lower Half of the Inner Case


71

5. The Male Audio Jack Cover


72

6. The Conductive Rings Wire Cover


73

7. The Nut Cover


74

EVALUATION

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75

Evaluation of Functional and Aesthetic

Aspects of the Design

Functional Aspects:

Positives:

The product successfully acts as a case and protects the phone and the earphones when

they are not in use.

The phone smoothly fits into the case and slides straight into the male audio jack.

The earphones roll smoothly straight up into the case

The connection works; when music is played on the phone, it goes straight through and

plays through the earphones, this is a major positive of the design.

Moulds to the hand well and feels comfortable to hold and use.

Negatives:

The design can be quite fiddly; to either unravel or wind up the cord the nut needs to be

loose so that the inner case can spin freely. Then the only way for music to play smoothly, is

when the nut is tightened forcing the inner case down on the pathway. This could get quite

annoying to continuously tighten and loosen the nut.

May be too large to fit in a pocket

The earphones have to wrap around the wiring and the brushes on the inside of the inner

case, it would be better if the wires and brushes were concealed.

It is quite a tight fit in the inner case for the earphones once they are rolled all the way up,

occasionally a part of the earphone gets caught and doesn’t allow for smooth unravelling.

Aesthetic Aspects:

Positives:

The product is very aesthetically pleasing, as the design is innovative and uses a nice blend

of acetal and polyethylene that distinguishes between the different cases.

The case is very sleek as all the sides are very smooth and well manufactured.

The logo provides a quality inclusion of personalisation to the design, this makes the design

look less plain and more professional.

Negatives:

The bottom half of the phone case was hard to manufacture as the slots that slide into the

upper half of the case are so thin. They have actually snapped off on one side, this is not

aesthetically pleasing, however it is not seen when the case is on the phone, and it doesn’t

have an effect on the function of the case.

The majority of the case has been manufactured by Albury Precision Engineering; however

there is one piece that is printed on the 3D printer as I decided to add it to the design just

before submission. It looks slightly out of place as it is a different material.


76

Impact of the Project on the Individual,

Society and the Environment

The Individual

The Retractable Earphone Case is designed to have a significant impact on the individual, particularly

an individual that is passionate about listening to music and has had troublesome times with

earphones. The product is designed to protect:

The iPhone – It acts just like every other solid iPhone case by protecting the whole phone

from being dropped, or bumped. It aims to limit the damage caused by external forces.

The Earphone cord – The earphone cord when not listening to music is hidden inside the

case. This will protect it from getting bent, cut or twisted when not in use.

The Earbuds – The earbuds will be secured so that they rest in a mould when they are not in

use.

By having the iPhone case and the earphones connected, it allows for easy access to earphones at all

times as they are right where you want them! On the back of the phone! This cancels the possibility

of losing your earphones when they are not in use. Not only are they easier to use, but it’s also

quicker to use as you simply have to unwind the earphones and they are ready to play music. The

problems of tangled earphones will be extinct. As the product is designed to be durable, it will

protect both the phone and the earphones, which leads to less money having to be spent on fixing

the phone and on new earphones. This will save individuals a significant amount of money that

doesn’t have to be spent.

By designing the product to be durable and to protect both the earphones and the iPhone it leads to

the case being significantly bulky. This will become annoying for some, as the unusual shape and size

will make it unable or uncomfortable to fit in some positions such as in pockets. The case will also be

marginally heavier than traditional iPhone cases which could also become a hassle to some

individuals.

Society

As the production of my retractable earphone case will lead to longer life expectancy of earphones,

this will lead to people having to purchase less earphones, leading to less money being spent so that

it can be saved and spent elsewhere. Through saving the wastage of lots of broken earphones it will

make people feel happy and not like they’re wasting their time purchasing expensive earphones.

By being able to access earphones almost constantly with your phone, it will lead to people listening

to music more often, this could be great and lead to increased happiness for the individual.

However, over time it could lead to hearing problems, which would be detrimental to the health of

society.


77

The development of the retractable earphones will not have that much of an impact on society,

however by increasing access to earphones, it could lead to more people listening to music on the

go, and ultimately, people beginning to prefer to listen to music all the time rather than socialise

with others.

The Environment (local and global)

Designing Phase

During the designing phase the design didn’t have too many negative impacts on the environment

both local and global. I used the 3D printer to print many different plastic prototypes of my design

over several months. Both the production of the plastic initially and the electricity required to power

the computer and the printer has had a negative impact on the environment, however only very

minor.

I used a variety of different metals such as brass, copper and aluminium to produce metal rings on a

few of my prototypes which led to off cuts of wastage that were most likely recycled. This is having a

positive impact on the environment as resources are not being wasted. However, I also used wires

with my prototypes, and off cuts from these wires couldn’t be recycled, so they were simply thrown

out.

Production Phase

I am getting my design manufactured by Albury Precision Engineering (APE). They are making my

design out of Acetal. Although Acetal itself does not contain any compounds that are dangerous to

the environment or one’s health, manufacturing Acetal does. The process of manufacturing Acetal

releases nitrous oxides and since factories have no use for the byproduct, it is released into the

atmosphere as waste. It has been discovered that, nitrous oxides contribute to the destruction of

stratospheric ozone and is a powerful greenhouse gas. The production of Acetal is harmful to the

environment both locally and globally.

Operational Phase

When my design is being used it will be having a minimal impact on the environment. However, after

it is discarded from the consumer, it will just be tossed in the garbage. This causes a problem

because Acetal has an exceptionally slow decay rate, which means that there is a buildup of Acetal

products in landfills worldwide. The other option for disposal is to incinerate it, however that

method has some harmful products including carbon monoxide.


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Relationship of the Project to the Project

Proposal The design brief was “To design and construct an earphone storage solution for Smartphone users

that can be used with a wide range of earphones”. My project has successfully linked itself to the

proposal and is definitely a solution to the situation.

The product prevents earphones from getting tangled when not in use as well

as protecting the earphones from getting damaged and broken. The design

isn’t very small; therefore it may be unable to be kept in a pocket. However,

the product is always going to be larger when it is required to store

earphones within it. In that case, the product is quite compact and takes up

only a small amount of room for the given design brief.

The product has successfully differentiated itself from already existing designs that are on the

market. The other products all have the earphone built into them. Whereas with my design the

earphones are separate, allowing for a wide range of earphones to be used. When the earphones in

the other designs break, the product becomes of no use. Conversely, with my design, just plug in a

different pair of earphones and the product is running again.

However, not all earphones can be used with my product. Some

earphones have a bent male audio jack, these jacks are unable to

be used with my design as they can’t plug into the female audio

jack. Also, some earphones have a volume button on them.

Earphones with the volume button on them can be used with the

case, however occasionally the volume button gets caught in the

winding process.

Ultimately, my design has addressed the situation and has

backed up the proposal. The product successfully removes

the major problem of tangled earphones from everyone’s

lifestyle. Although, disappointingly not as much of a wide

range of earphones can be used as expected with the

product.

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retractable earphone case

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