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CLARICE PRANYOTO
Aluminum Airpod
IPD 5010 Spring 2023
Surface Modeling in Solidworks
The objective of the this project was to gain experience on the Mini Mill. To display my enthusiasm for Apple's innovation, I decided to machine a giant Airpod! I began this processing by measuring and modeling my own Airpod. I strengthened my surfacing skills using tools such as Guide Curves, Boundary Surface, Knit Surface, and more to accurately portray curvature continuity. Below is my first ever attempt at rendering in Keyshot.
Developing a Fixture Plan and Toolpaths
The organic curves of the Airpod added complexity to the manufacturing plan. Due to prominent undercuts, it became clear that at least one 180° flip would be required to access all necessary features. A vertical orientation was considered but ultimately dismissed, as the slender stem lacked structural rigidity, making it difficult to support without inducing vibration or deflection during cutting. The manufacturing plan went as followed:
STEP 1: Rough out top half of the geometry, leaving posts for #10-32 screws. I wanted to minimze the height of these posts but also ensured proper thread engagement. I opted for a 2x diameter thread engagement: Tapped Depth = 2 x 0.19" = 0.38"
STEP 2: Flip the stock 180Ëš and fasten it to a fixture. The fixture was machined to have #10-32 clearance holes and served as the new datum.
STEP 3: Machine out the speaker cavities to later fill with resin.
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Resin and Polishing
Final Product
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