Goal:

Design an aesthetically pleasing and durable sink organizer capable of holding 1–2 brushes and 1–2 sponges while withstanding daily use.

Requirements:

• Fit within build plate restrictions using a two-part assembly.
• Utilize a secure and functional snap-fit connection.
• Minimize material usage while ensuring durability through structural optimization.

Design Highlights:

Snap-Fit Assembly:

• Implemented a cantilever snap-fit to join two 3D-printed components without adhesives.
• Conducted multiple iterations and prototyping to achieve a perfect fit with no wiggle, following industry design recommendations.

Finite Element Analysis (FEA)

• Identified high-stress areas and optimized reinforcement to balance durability and material efficiency.
• Loading Scenarios:
• Scenario 1: Simulated perpendicular force on brush head cutouts to identify stress concentrations.
• Scenario 2: Evaluated edge loading to account for inadvertent user-applied forces.
• Scenario 3: Analyzed forces normal to the surface with dynamic constraints to reflect real-world use.
• Arbitrary high loads were applied to highlight hotspots, guiding design improvements.

FEA Considerations:

• Addressed mechanical variability of 3D-printed PETG material due to print orientation, speed, and machine differences.
• Acknowledged the need for further material testing (e.g., tension, compression, torsion) for accurate modeling.

Outcome:

The final design achieved a durable, functional, and visually appealing sink organizer that met all client requirements:

• Secure Assembly: Perfect snap-fit connection.
• Optimized Structure: Reduced material costs while maintaining structural integrity.
• Client Satisfaction: Delivered a robust and elegant solution, exceeding expectations.