Clever Design and Optimization for Small-Batch Manufacturing using high quality Multicolor FDM 3D Printers.
Tiny Whoop “Fleet Box 65mm”
This design was the one that began my endeavor in 3D print farming. Originally a basic design I made for personal use, some community members took a liking to this case I created to snugly hold 4 “65mm” sized micro racing drones. I was contacted by Jesse Perkins, the owner of tinywhoop.com, and we made an agreement for me to manufacture and sell them on his store.
I tweaked my original design to optimize it for 3D printing in larger quantities, considering the tolerances of the lid as well as the shape of the wall contours to ensure repeatable printing. I added Tiny Whoop’s official logo and sized it properly to capture all details. I also performed test prints to measure material use per part, as well as considered electricity usage and machine maintenance necessary to begin manufacturing.
6 colorways were chosen and filament was ordered and managed to complete the desired part count of 50 units for the first production run. I was able to complete the job in just over a week using 2 machines, printing around the clock. Upon release, the community loved the design. The original batch sold out in just a few weeks and I have since created a second batch of close to 100 units.
Tiny Whoop “Prop Popper Kit Box”
For my second project working with Tiny Whoop, I was tasked with creating a clever case for the Prop Popper, a micro drone propeller removal tool that was developed by another community member and also sold in the TW store. I went through multiple revisions, but eventually landed on a small handheld case with a section in the center that snugly holds the tool, and bays on either side to hold propellers, labeled for the direction that they spin. This allows the user to not only have access to their tool, but also the desired propeller(s) they will need to replace the prop they are taking off.
A priority in my design process for this project was to match the design style of the fleet box. This way, my products would have a “family of form” as well as matching colorways for a uniform look. I also took time to refine the user interaction with the tool slot especially, and went through 4 revisions with Jesse to get the shaping just right.
Tiny Whoop “Fleet Box 75mm”
After the success of the original Fleet Box 65mm, I received over 15 personal messages and comments from community members requesting a version for their “75mm” sized micro drones. I was excited to begin, but It wasn’t as simple as scaling up the original design.
The different frame options for 75mm class of drone come in different profile shapes, some with a lower battery tray, and others with a uniform shape and a battery tray tucked up underneath. Because of this, it was challenge to create a profile slot that fit all options universally, and made sure they were secure. I accomplished this by thickening the wall at the bottom of each slot and creating a recess for the battery of the frame with the lower tray.
