Week 11-12: Production process

In these two weeks, we mainly focused on the producing process; based on the material testing on cork wood and aluminum metal, we discovered that cork sheet is too soft to make the inner structure of the VR glasses: face mask and the phone casing. Therefore, we decided to add the material of MDF wood in order to increase the thickness of these two parts.

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Step 1: 3D model

Before starting to do the laser cork, we first made the 3D model of overall product design on Solidworks to ensure the dimensions are clear and fit with each part.

Top, right, front and isometric views with dimensions.

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Step 2: 3D model render

We did the 3D model again on Maya software, and add the texture to see what the appearance of the form will look like when using the real material including wood and metal.

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Step 3: Laser cut the MDF wood

Phone casing to lock down the phone during the video is playing.

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Step 4: Cut the cork sheet and aluminum board by hands with scissors

During the cutting phase, we left 2 inches extra length on right and left sides for cork sheet(wood) to avoid we cut it too short. For the aluminum board (metal), we cut a rectangle first and then trim it slowly to make the round edge.

Cork sheet was purchased at Canadian Tire. There is a dimension map on the back of the sheet. Therefore, it saved us time to do the multiple checks with dimensions.

Fixing the size of black rubber to reduce the sharpness of the edge from metal

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Step 5: Sand the edges of the metal and wood

During the finishing phase, we decide to use hand file and sand paper to sand the edge of the metal because we felt that belt and disc sanding machine is too fast that it is easier to sand too much. Also, we make a hole with the hammer to lock down the metal and wood easily.

We make a hole to lock down the aluminum and MDF laser cut wood.

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Step 6: assembly the wood and metal

During the assembly phase, we use screw to lock down the face mask and phone casing. And, the image below are the process before the final assembly.

The hinge is used on the front casing to lock the front casing and main casing.

Closed up shot to show the detail of how the lenses rings (3D printing PLA plastic ) hold the lenses and lock down to the face mask.

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Final physical model

Top view of Horizon VR glasses

Front view of the Horizon VR glasses

Front view of the Horizon VR glasses (after open the front casing)

Back view of Horizon VR glasses