FusionBell
Doorbell made with different production methodes
FusionBell is a wireless doorbell with an accompanying speaker created by combining multiple different production methods.
Course
Industrial Production
Tools
Siemens NX Protomax Waterjet ISEL Sinterit Lisa SLS Formlabs Form3
Project Type
Three-person academic project
Date
February 2024 - June 2024
CONTEXT
The project focused on designing and manufacturing a wireless doorbell system, including both the transmitter (doorbell) and receiver (speaker), with detachable connections to ensure easy assembly and maintenance.
Combination of Production Techniques: Required the integration of multiple industrial manufacturing methods while ensuring efficient assembly.
Manufacturability: Careful consideration of materials, tolerances, and assembly methods to achieve a high-quality, repeatable final product.
Electronics Integration: Repurposed components from an existing doorbell were seamlessly incorporated into the new design.
Real-World Approach: The process mirrored industrial production standards, emphasizing efficiency, precision, and scalability.
SOLUTION DEVELOPMENT
The design phase began with an analysis of existing doorbells to understand their structure, materials, and assembly methods.
Thermoforming: A CNC-machined PU foam mold was created and used for thermoforming the doorbell housing, ensuring a lightweight yet durable casing.
Injection Molding: Initially used for the button, but inconsistencies in material flow with a 3D-printed mold led to an alternative production method.
Silicone Casting: Applied for the nameplate, allowing for precise lettering and a smooth finish.
Custom Component Design: All parts were developed to ensure compatibility with the reused electronics.
SOLUTION DEVELOPMENT
Sheet Metal Forming: The speaker cover was shaped using a hydraulic press and a custom 3D-printed die, with various techniques tested to refine the process.
Waterjet Cutting: A decorative brass plate was precisely cut to achieve clean edges and accurate dimensions.
3D Printing: Used extensively for prototyping, comparing SLS and FDM printing to evaluate material strength and accuracy.
Process Optimization: Challenges such as material shrinkage and tolerance mismatches required iterative refinements, ensuring the final components met industrial standards while maintaining efficiency.
OUTCOME
The final wireless doorbell system successfully demonstrated the correct application of industrial production techniques.
Precision Manufacturing: All components were produced with high accuracy, ensuring proper assembly without adhesives, as required.
Integration of Techniques: A combination of thermoforming, CNC machining, and sheet metal forming resulted in a durable and aesthetically refined product.
Production Insights: Gained valuable knowledge on tolerances, material behavior, and process optimization.
Design for Manufacturing: The project reinforced the importance of efficient, scalable production methods, providing a strong foundation for future industrial product development.
