AXON BOLT 2
Embedded Files
Overview
Product: An IoT-enabled civilian self-defense device designed for non-lethal use
Project Goal: Create the next generation product in the Bolt series, Bolt 2
Responsibilities:
Team Lead
CAD Owner
Quoting
Prototyping
Design for Manufacturing (DFM )for injection molding, overmolding, sheet metal, and cable assemblies
Interfaced with manufacturers during DFM process
2D/3D CAD documentation
Fixture design for PCB/FPC testing, laser centering, and adhesive curing
Project Challenges:
Working with high voltage tech
Tight schedule
Design Process
EVT - Engineering Valuation Testing
DVT - Design Valuation Testing
PVT - Production Valuation Testing
CAD Phases
Prototype CAD
In this phase, CAD is used strictly for exploratory purposes, testing different design solutions, layouts, and ideas rapidly.
Working CAD
In this phase, all viable solutions from the prototype phase are refined. We develop works-like, feels-like, and looks-like models, iterating until we achieve the best possible solution. We maintain parametric modeling practices via top-down modeling methodology throughout this process.
MNF. (Manufacturing) CAD
At this phase, the industrial design (ID) is locked. Skeleton files are omitted to eliminate the risk of unintended changes through different parts. Any necessary changes are made at the part level and must go through strict approval.
Release
In the release phase, all CAD changes and drawing documentation are finalized. A hand-off is completed, providing drawings and STEP file of the fully assembled product.
Early Development
During the early phase of the project, we constantly adapted to evolving project specifications as the Industrial Designers (ID) finalized their design. Despite these uncertainties, we identified a few constants to work on, including:
Selected firing cartridge
Selected High Voltage (HV) board
Battery operation
Front door
Battery door
Handheld design
With these constants, we aimed to optimize the housing to incorporate the cartridge, HV board, batteries, and doors. This included optimizing the HV board's overall volumetric footprint to make the product as handheld-friendly as possible. .
Along with designing the housing, we also designed the battery door. The early battery door concept was a four part assembly incorporating a spring latch and jumper for the batteries.
Blue frame for hinging onto the housing
Red door for latching
Leaf spring as the spring latch
Custom jumper
This early solution proved viable through prototyping with a handmade leaf spring and 3D printed blue frame and red door.
Early design work on the front door was aimed to replicate the battery door design. The main exploration for the front door involved determining the allowable space for the hinge and understanding how it would impact the overall design.
Battery Door Assembled
Front Door Assembly
Battery Door Exploded
Early Battery Door Concept Demos
20-1111_early_bat_door_concept_1.MP420-1118_early_bat_door_concept_2.MP4CAD File Architecture
This is a diagram breaks down of the relationships between top-level and lower-level skeleton (SK) files, illustrating how they are interconnected.
CAD File Ownership
Files Owned:
SK-ID
SK-MAIN
SK-GRIP
SK-CHASSIS
SK-BATTERY-PACK
SK-LV-FPC
Partial Owner:
SK-ENCLOSURE
Parts:
Chassis Contacts
Chassis
Interposer-FPC
Parts (continued):
Grommet
Shell Cover
LV-FPC
Window
Battery Tube
Battery Tube Contact
Battery Tube Spring
Battery Pack
Battery Pack Contacts
Battery Door
Enclosure
SK-ID File
SK-Main File
SK-Grip File
Chassis Contacts
Chassis
Interposer-FPC
Grommet
Shell Cover
LV-FPC
Window
Battery Tube
Battery Tube Contacts
Battery Tube Spring
Battery Pack Contacts
Battery Pack
Battery Door
Enclosure Left
Enclosure Right
Draft Checking
Suggested Factory Changes
Gate/Ejector Placement
Drawing Documentation Approval Process
Manufacturing Support
LV-FPC Testing Fixture
HV-FPC Testing Fixture
Shell Door Adhesive Pathing Fixture
Chassis Assembly Curing Fixture
Post Potting Testing Fixture
Laser Centering Fixture
Enclosure Adhesive Pathing Fixture
Enclosure Assembly Curing Fixture
Lessons Learned
Key Takeaways:
Gained comprehensive experience in navigating the entire design lifecycle of a new product, from inception to completion
Collaborated closely with a foreign manufacturer to devise solutions for producing our parts with their equipment
Provided support to manufacturing/assembly teams, gaining insights into their process of ramping up for production
Improvements:
Reduce material waste on the enclosure by eliminating unnecessary features
Enhance the battery door design to enhance user-friendliness and prevent sticking issues experienced by some users
Refine the front door design to improve its spring-off mechanism upon activation
Google Sites
Report abuse