Design Progress | Week 4

Dates: 09/10/25 - 09/16/25

This weeks progress to the NAVI involved both the design and electronics fronts of the project. I updated the CAD models and completed the first set of renderings for the individual components of the facial support and collector. In the Innovation Studio, I used an orbital sander to refine the rough edges of the IR sensor housing on the front plate. The print also produced a slight protrusion along the border of the nose guard, which I smoothed out during this session but found the dimensions for the portion pertaining to the area of the nose is not fitting properly.

After reviewing the initial prints, I revised the design approach by merging the collector and the facial support brim—similar to the integration of the front plate and component housing—before preparing a reprint. During this stage, I also optimized the TPU 3D print settings after a couple of test prints. Since TPU requires roughly double the print time of PLA, I conducted calibration tests to fine-tune the temperature thresholds and ensure consistent print quality.

Also, I was able to procure and build a Heat Set Insert Tool with Threaded Knurled Nut Brass Inserts for the use of connecting the entire NAVI system together. Modifications to the CAD drawing may be required.

On the electronics side, I transitioned from KiCAD to LTSpice for circuit simulation. KiCAD’s Mac limitations, particularly the need for custom EDA/CAD models for each component, made LTSpice the more practical choice. I began following LTSpice tutorials and initiated schematic design work, though compatibility has required using Windows PCs in the lab.

https://www.youtube.com/watch?v=rQxVv8VDda4