fractional

a set of custom visual measuring cups shaped like the fraction they measure

stainless steel, brass, various hardwoods
mill, sheet metal forming, TIG welding, brazing

ME 103, Designing and Making • Spring 2022

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Project Brainstorming | Conceptual Sketches

  • Stacking Bento Boxes

  • Archery Bowstand

  • Hangboard

  • Fountain

  • Visual Measuring Cups

  • Tool Organizer

  • Book Stand

  • Sharpening Stone Holder

  • Mechanical Clock

  • Chess Board and Pieces

Stacking Bento Box

Product Overview and Metal Box

As shown, each box would stack on each other. This allows for easy storage and portioning. The metal box would need to be waterjet cut and formed using a finger brake before being TIG welded.

Metal Box & Wood Lid

Continues to show how metal box would be formed. Lid would be made out of wood and routed to form a lip and a recess in the top.

Handle

The bento box that sits on the top of the stack would need a carrying handle for easy transport. This would be cast for a unique shape.

Iteration: In-Depth Sketches

I selected 3 ideas from the original 10 to define and explore further.

Incense Fountain

Product Overview

This is designed to be a desktop fountain that also burns incense. In the event that plumbing is too hard and water isn’t possible, this can also just be an incense holder.

Waterfall Bar and Wood Dish

A bar to create the water design desired would need to be cast out of bronze. A wooden water dish would be turned on the lathe.

Assembly

Shows basic parts assembled. Decorations could be added as needed.

Visual Measuring Cups

Product Overview

Designed to be a set of fractionally shaped measuring cups to eliminate the need for labels.

Cup Body

The cups would be created from sheet metal, formed via slip roller, and TIG welded together.

Handle Design

The handle would be made from wood for balance and aesthetics. A piece would need to be machined to connect the handle to the cup.

CAD Model | Measuring Cups

I chose to pursue the measuring cup project. I felt that it provided the most flexibility (as more or less cups could be made as needed) and provided options to incorporate a range of fabrication processes. The next step was to create a CAD assembly to determine dimensions for each part.

Prototyping | Sheet Metal Cups

  • Prototyping

    I first wanted to make a cup out of cheap mild steel to practice the forming process and TIG welding. As you can see in the above image, it is difficult to get the exact diameter needed.

  • Mounting Fixture

    Due to the difficulty in getting the exact dimensions needed, a unique clamping solution had to be developed to create strong welds.

  • TIG Welding

    The welding for each cup consisted of a butt joint to create the walls and a corner joint to attach the bottom of the cup. Since this was my first time TIG welding, I used mild steel (as it is easier to work with).

  • Weld Penetration

    A good weld needs to penetrate through the part. Since the cups need to be watertight, this is especially important - hence my focus here on achieving good penetration.

  • Finished Prototype

    The goal of this prototype was to try out the processes needed for my final project on cheaper and easier materials. As shown above, this was successful.

Fabrication | Cups

  • Cups with Welds Finished

    These are the 4 welded cups, with good weld penetration and in the desired shapes.

  • Waterjet Cutting

    To get the precise dimensions and angles I needed out of my sheet metal pieces, I utilized a waterjet cutter. This is an image of the cutting program.

  • Slip Rolling

    After cutting out the pieces of sheet metal, they needed to be rolled to create the round walls of the cup. I’m using a slip roller here to achieve the desired curvature.

  • Welding Guides

    My first mild steel prototype was not perfectly round as the force of the clamp squished the steel. To combat this, I 3D printed guides that could be used to maintain the shape of the metal during a tack weld.

  • Welds on Part

    Finished welds on each cup.

  • Finished Cups

    I ground down the welds on the outside of the cups for a smooth finish.

Fabrication | Metal Handle

  • Metal Handles Attached to Cups

    The brass pieces are brazed to a small piece of stainless steel sheet metal, which is then riveted to the main body of the cup.

  • Sheet Metal Interface

    Since brass is not food-safe, we cannot directly attach the handle to the cup. This small piece of metal serves as that barrier.

  • Milling Brass Pieces

    4 brass pieces needed to be made to attach the handles to the cups. These pieces had a groove cut to mate with the handles and a rounded side to match the curvature of the cups.

  • Brazing Handle Pieces

    Pieces of the handle were brazed together, meaning that a small amount of solder was heated with a torch to join the pieces together.

Fabrication | Wood Handle & Display Rack

  • Full Handle Attached

    Full assembly of cups with unfinished wood.

  • Rough Wood Outline

    A general profile of the wooden handle was achieved via hand router.

  • Oiled Handles

    Handles being finished with linseed oil

  • Oiling Display Rack

    Finishing display rack with linseed oil.

  • Finished Cup

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