Andrew Puddefoot

01

Ray the Flashlight

Custom handheld torch with integrated LED and trigger switch

Overall Length

186.06 mm

Overall Height

57.4 mm

Lens Diameter

Ø5 mm

Material

PLA plastic

Power Source

2× AA battery cradle

Light Source

LED with lens

Control

Mechanical trigger switch

Status

In active use

Design Challenge: Surface Modeling & Ergonomic Form

Designed a handheld flashlight for a child user, requiring careful attention to ergonomics and durability. This project was the first time working with advanced surface modeling techniques in Fusion 360—creating smooth, organic forms while maintaining structural integrity. The design accommodates a 2×AA battery cradle, mechanical trigger switch for power control, and integrated LED lens. All components required precise fit and tolerance management to ensure reliable assembly and longevity.

Lessons Learned & Manufacturing Insights

This project taught the importance of understanding real-world fit and user interaction in mechanical design. Surface modeling revealed how small geometry changes affect manufacturability and assembly. The trigger mechanism required iterative design to achieve smooth, reliable motion without binding. Testing through 3D printing iterations proved invaluable for validating tolerances and identifying assembly issues before finalizing the design. Every component serves a purpose—nothing is decorative.

02

Interactive Sound Robot

Custom mechanical design with integrated electronics and audio module

Design Method

Blender → Fusion 360

Key Challenge

Electronics integration

Components

Sound module, battery, switch

Material

PLA plastic

Tight-fit tolerances

±0.15 mm

Component tolerances

±0.25 mm

Iterations

Multiple print tests

Status

Fully functional

Complex Assembly: Mechanical + Electronics Integration

A custom robot design requested by a 15-year-old with specific design requirements including audio playback capability. The design workflow combined Blender for artistic sculpting with Fusion 360 for precise mechanical engineering. The challenge was integrating a recordable audio module (purchased component) within tight spatial constraints while maintaining structural integrity. Required designing custom holders for circuit board, speaker, and battery with zero wasted space. The head-mounted button needed to actuate the sound module switch reliably.

Tolerance Strategy & Practical Manufacturing

Most parts used ±0.15mm tolerances for optimal fit, while smaller components and support-interface parts used ±0.25mm tolerances to account for 3D print variability. This iterative tolerance approach came from testing multiple print iterations. The battery compartment required absolute precision to prevent short circuits while remaining removable for maintenance. The switch button actuator in the head required smooth, consistent motion without binding—solved through careful geometry planning and test printing. This project demonstrates the critical importance of understanding manufacturing constraints at the design stage.

03

Refrigerator Shelf Brackets

Structural design for appliance repair and reinforcement

Material

PETG plastic

Reason for PETG

Enhanced strength & durability

Application

Load-bearing structural repair

Design Type

Dual-component system

Material Selection for Functional Requirements

Designed to replace a broken refrigerator shelf support system. This project emphasized the importance of material selection—PETG was chosen over standard PLA for its superior strength and temperature tolerance, critical for sustained appliance use. The design includes a glass-slot interface for secure shelf positioning and careful weight distribution to handle dynamic loading. The dual-component design (front and rear brackets) ensures stability while accommodating the existing fridge frame geometry. This demonstrates understanding of real-world manufacturing constraints and material properties beyond aesthetics.

04

Parametric Box with Hinged Lid

Parametric design approach to mechanical assembly

Design Approach

Parametric modeling

Primary Purpose

Tolerance validation testing

Hinge Mechanism

Filament pin joint

Material

PLA plastic

Tolerance Validation & Design Iteration

Created as a deliberate test of tolerance management and mechanical assembly. The design uses a simple but elegant approach: a piece of standard 3D printer filament serves as the hinge pin, requiring extremely precise tolerances to allow smooth motion without binding or play. This project validated tolerance strategies later used in more complex designs. By keeping the design simple and focused on a single mechanical challenge, it became an excellent learning tool for understanding how small geometry variations affect assembly and function. The parametric approach allows rapid iteration of dimensions to find optimal tolerance ranges.