VIGA
       
     
Butterfly Whistle Edit - Handle.jpg
       
     
Butterfly_Whistle_Details (1).JPG
       
     
Early Prototyping
       
     
Mid-Stage Prototyping
       
     
Late Prototyping
       
     
Working in Onshape
       
     
DWG
       
     
Pattern Board
       
     
IMG_3365.JPG
       
     
Early Cast Part
       
     
Silver-Brazing
       
     
Post-Brazing
       
     
Press-Fitting a Turned Endcap
       
     
IMG_5240.JPG
       
     
Sonali Singh Slide VIGA 2.jpg
       
     
Butterfly Whistle
       
     
VIGA
       
     
VIGA

Final Project for ME 203 - Design & Manufacturing

Description: A combined-function safety whistle capturing the beauty of the common mime butterfly, VIGA is a useable artistic piece conveying a message about pacifism and personal protection.

Processes: Pattern-Making, Sand Casting, Milling, Turning, Brazing, Press-Fitting

Butterfly Whistle Edit - Handle.jpg
       
     
Butterfly_Whistle_Details (1).JPG
       
     
Early Prototyping
       
     
Early Prototyping

I made a number of whistles out of aluminum cans to observe whistle characteristics (air flow).

Mid-Stage Prototyping
       
     
Mid-Stage Prototyping

I used multiple PVC pipe whistles to look at whistle length/pitch and the fipple characteristics (angle, wooden insert length, height)/volume.

Late Prototyping
       
     
Late Prototyping

I tested the feasibility of specific processes, the primary focus being the method of connecting a cast-piece to a machined piece.

Working in Onshape
       
     
Working in Onshape

I decided to try working with OnShape's cloud-based CAD platform for this project - I found that it was missing a number of key features but enjoyed the convenience of working on the cloud.

DWG
       
     
DWG

an Onshape Drawing of the assembly

Pattern Board
       
     
Pattern Board

I carved modulan using belt sanders and rotary tools to create my pattern, gate, and runner, and the dimensions of the casting collars for the pattern board.

IMG_3365.JPG
       
     
Early Cast Part
       
     
Early Cast Part

I fine-tuned the pattern for a smoother cast-finish (primarily addressing sand-wash using draft angle, a finer sanding grit, more layers of shellac).

Silver-Brazing
       
     
Silver-Brazing

Silver, with a lower melting point than brass and bronze, was the material I used to braze the parts; the cast bronze piece required more time to heat than the thinner-walled whistle body.

Post-Brazing
       
     
Post-Brazing
Press-Fitting a Turned Endcap
       
     
Press-Fitting a Turned Endcap

2 thou tolerance

IMG_5240.JPG
       
     
Sonali Singh Slide VIGA 2.jpg
       
     
Butterfly Whistle
       
     
Butterfly Whistle