Design Progress | Week 10

Dates: 10/22/25 - 10/28/25

During this weeks progress, the primary focus was on refining the headset’s front plate design and addressing complex alignment issues with the face plate. Over twenty hours were dedicated to iterating through multiple design versions in Fusion 360, concentrating on finalizing the curvature, internal supports, and mounting geometry to ensure accurate alignment and strength. Despite significant effort, directly modifying the face plate geometry proved extremely challenging. Small adjustments to its curvature often caused constraints or reference sketches to break, requiring repeated rework. Much of the week was spent balancing with fit accuracy, performing printability checks to avoid thin walls, poor overhangs, and alignment gaps between the two components.

Compounding the design challenges, the Creality K1 Max printer experienced a critical hardware issues that caused additional delays. Through the week, several different project prints from other groups resulted in the printer needing to be disassembled and reassembled to replace a clogged and damaged nozzle and restore consistent extrusion performance. The maintenance process included cleaning the print head and then replacing the printhead due to damage, recalibrating the extruder, and testing filament flow before production could resume. These repairs were necessary due to prior print failures from other projects, which had compromised print quality and reliability. While the week’s productivity was impacted by both mechanical and design setbacks, by the end of the period the front plate had reached a more stable form and refinement before print testing.

Nozzle replacement

Print failure

Print failure 2