Design Progress | Week 3
- Sep 9, 2025
- 2 min read
Dates: 09/03/25 - 09/09/25
This weeks progress involved both the physical prototyping and electrical systems of the NAVI project. The CAD model was updated to include both the front plate and the component enclosure as separate modules as one main component. While both parts printed successfully, the component enclosure proved to be too thin and flexible, potentially compromising its structural integrity when attached to the front plate.
To improve assembly methods, I began researching heat set insert tips and soldering tools that would enable more secure fittings for both testing and integration with the custom PCB as well as the full enclosure itself. At the on-campus Innovation Studio, I used tools like the orbital sander to clean up rough edges on the front plate caused by support structures from the complex 3D print, which currently takes between 14–28 hours per run. In addition, I printed the next major component—the faceplate body—which will also require post-processing at the lab to remove printing imperfections.
On the electronics side, I began exploring KiCAD and LTSpice to aid in schematic design and circuit simulation. During testing, I identified a potential issue with the motor control drivers: the digital signal to the haptic motors may require both a multiplexer and a MOSFET due to high input resistance concerns. To address this, I updated the power budget to replace the outdated Darlington Array Transistor with a more efficient MOSFET IC. Missing also from the power budget was an LED from one of the push buttons, but that has been corrected. This MOSFET upgrade should improve power efficiency, provide faster switching times, offer built-in thermal protection, and include integrated flyback diodes for load protection.
The “Gantt Chart – Design” was also revised to reflect the updated timeline for printing and assembling the wearable components along with the timelines of other tasks that should be completed.
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