Final Project

For my final project I wanted to do something that someone can wear but also something useful. The idea of electronic wearables inspired me for this project. I decided to make a type of Cast for a arm. This Cast would be used after the regular cast is take off, the purpose is to provide extra protection for someone while they do therapy or just walking around as it protects from bump. I thought of this idea because when I broke my arm there was nothing like this provided to me. I present to you the Exo-Cast.

My first step was to design how it would be cut on the laser cutter. I used inkscape to draw this picture of what I would put on the laser cutter.

At first I cut the design using cardboard that way I wouldnt risk anything and also I was thinking of using it as a mold.

I used the same materials we used for molding and casting the pink and blue liquds and put the card board peices on it in order for it to make a mold.

Unfortunely the next day as the liquid hardend I tried to remove it but it looked like a mess.

The next thing I tried to do was to mix the liquid rubber and let it dry by itself. You must be careful because it can leak through the sides. Also I would reccomend for you to place it on top of plastic. Something like cardboard or wood isn't going to work well.

The Next day everything dried and I picked it up and it was perfect for what I needed. It was flexiable and had a good amount of thickness. The next step for me was to put it on the laser cutter. I used the same design that I cut the card board. It took a very long time for the holes to cut. I had to go run the pattern for maybe 10 times because the material was hard to cut for the laser cutter.

After being cut in the laser cutter I hand plucked the small holes. The removed easily.

After taking out the pieces I rinsed it in water and just put it aside for a bit. My next step was to put lights on this thing which my teacher had suggested. I went into eagle and designed simple LED Boards.

I then milled the boards which took a while... but not too long.

I then was soldering the pieces for the LED. I put the Led on the last and connected the wires to the aridino board.

The next thing I had to do was program ardunio on my computer beofre plugging it into anything. At first the lights were slow so I decided to speed it up.

This picture below is what one of the led boards look like. I would use the metal legs on the leg to stick it on the cast then cut the legs short so it doesnt bother who ever is wearing it.

I programmed it with arudino for the lights. I wear the cast with another cotten clothe over my arm then put on this cast. Below are videos and pictures of the result.

I enjoyed taking fab academy and during this time period I learned so much in a quick period of time. Thanks to my teacher and other people for teaching this amazing course.