IDEA DEVELOPMENT
Generated two conceptual designs
 Selection guidelines:

1. Reasonably Sophisticated – Complexities
and Geometric Variations
2. Reasonably aesthetic and expressive - visual
impact, expressing theme
3. Avoid complication in machining strategy
DISCARDED DESIGN
• Lack of sophisticated
details –
Simple
and
repetitive
geometries


a 3D shape
of a
badminton
unique ratio
of mass
distribution
• Insufficiently expressive Too abstract
• Complication 3D shape
SELECTED DESIGN
• Sophisticated details –
Complexities
and
Variations
• 2D shape of a
badminton and
racket
• Sufficiently expressive –
clear shapes and texts
of badminton
• Badminton Text
• Avoided complicated Structured layers
Design Description
• Nice to look
• Easy to sketch and
mill
• No sharp corners
• Light in weight
• Have only a
rectangular footprint
Crude sketches
The Base of trophy
• A rectangle hole of matching the trophy body is created
on the base. The trophy can be placed perfectly into the
hole of the base.
Trophy Body
Materials and Properties

Trophy Base: Stainless Steel

Trophy Body: Tungsten

Weight: 1.611 kg

Volume: 1.44 × 10-4 m3
List of Tools Selected
No.
Tool Name
Diameter
Cor.
Type
rad.
1
END MILL WITH
Rad.
Type
12.0 mm
2.0 mm
Bull endmill
Corner
END
1.0 mm
0.5 mm
Ball endmill
Full
END
3.0 mm
1.5 mm
Ball endmill
Full
END
5.0 mm
2.5 mm
Ball endmill
Full
1.0 mm
0.0 mm
Flat endmill
None
RADIUS – 12/R2.0
2
BALL-NOSE
MILL - 1
3
BALL-NOSE
MILL - 3
4
BALL-NOSE
MILL - 5
5
FLAT END MILL - 1
Clamping of Workpiece

T-slot Toe Clamp

L-shaped bracket
Clamping of Workpiece
Trophy Base
Clamping of Workpiece
Trophy Base
CAM
TROPHY BASE
3 Processes
 1 Dynamic Optirough
 2 Scallop
First Process
Dynamic Optirough
 END MILL WITH RADIUS – 12/R2.0

Second Process
Scallop
 BALL-NOSE END MILL- 5

Third Process
Scallop
 FLAT END MILL - 1

Trophy Body
3 Processes
 Dynamic Optirough
 Scallop
 Pencil
Forth Process
Dynamic Optirough
 END MILL WITH RADIUS – 12/R2.0

Fifth Process
Scallop
 BALL-NOSE END MILL - 3

Sixth Process
Pencil
 BALL-NOSE END MILL - 1

Combining the trophy

J-B Weld 8276 KwikWeld Quick Setting
Steel Reinforced Epoxy glue