I started my design in a new way- I decided to create models with clay so I could freely manipulative the structure as I wish. I got the idea from Creo Freestyle. starting with a block and sculpting down and refining.
From this process I decided that my grill would sit on the lip so it would be flush.
On the same plane I draw another circle at 66mm and remove 3mm of material. this created the basis for my lip.
I then chamfer the underside to reduce materials, being economical reducing price as one cubic cm costs 40p .
Also the front for aesthetic purposes.After reading the advice from the University handout it advised I keep the design as simple as possible, avoided irregular shapes and keep the design uniform.
I save the file as an STL (Standard Tessellation Language) ready for rapid prototyping and send it to print. I print this component in a Fused Deposition Modeler and print in ABS plastic.
After 30 mins my components are printed, they are then steeped in an alkaline bath to remove support structures and left for a few hours. Once printed i decide not to paint them black as I like the white of the ABS and it contrasts well against the black.
Here are my two developed Grill designs I created them on Corel Draw and will export my selected one to be cut on the laser cutter. I need to make sure that cut lines are set to hairline size.
Design one was inspired by sound waves. Design two was inspired by the horn shape abstracted.
I have decided to go with the modern horn influenced grill as after spending time looking at this representation I believe it compliments my design yet does not stand out too much. I think it works better as a whole considering the nature of my speaker being a horn.
The grill is laser cut on the same plastic I have used for my side panels as i have plenty of the plastic and also it ties in with the colour scheme.
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