5 Weeks
Spring 2023
304 stainless steel
Plasma Cutting
Finger Break
TIG welding
DFM
Thermal Analysis & Simulation
User-Centered Design
Workflow Optimization
Sheet Metal Design
Whenever I go to a coffee shop and they have a new selection of coffees, I'd want to try as many of them as I can; but I don't want to buy 3 cups of coffee!
Can I design a system that makes it easy for a barista to hand brew 3 sample cups of coffee at once.
This project was my first time working with sheet metal, so I made a deal with a sheet metal professional in Irbid Jordan: He walked me through the process of making the drippers, and I gave him a crash course in fusion 360.
To hand brew three coffee at the same time, the design needs to be slim and tesselate → The hexagonal shape and 30° angle instead of the conventional 60°.
I started by modeling the geometry and 3D printing
I adjusted the width of the base so it sit nicely on most cups, and made the handle a little bit thicker.
I then moved to simulate the heat transfer to make sure the handle won't be too hot. the first result wasn't great! the handle was reaching a temperature of more than 52℃
I then separated the base from the body of the dripper and made the side point the only contact point which lowered the max temperature of the handle area to less than 30℃
I then moved to manufacture a set of three drippers:
Started with laser cutting the 1 mm stainless steel sheet:
Used the finger break to bend it into shape
TIG welded the seams and finished them
Thoroughly washed the dripper and they're now ready to use!
I started testing the drippers with my brothers who run a coffee a business and we developed a recipe together
This project was really fun and I learned a lot about sheet metal building it!
