Project Cradle

 This is a research and development initiative project that focuses on designing a modular book cradle that can be fabricated in-house. The design accommodates books of varying dimensions, eliminating the need for engaging external vendors for custom stands, thereby reducing labor costs and material waste.

Introduction

Purpose of Project

This project aims to address a longstanding challenge in the fields of museum curation, exhibition design, and display solutions. One of the recurring issues involves the replacement of book displays with new collections, each requiring custom-made stands due to the unique dimensions of individual books. The frequent redesign and fabrication of book cradles result in material waste, labor inefficiencies, and increased costs.

The Current Approach

The standard approach involves measuring book dimensions and commissioning vendors to create custom laser-cut acrylic stands. However, this process has several issues, such as delays in receiving quotes, which can hinder urgent requests. Furthermore, if a new design is required quickly, vendors may be unable to accommodate the request, resulting in delays, limited flexibility, and inefficiencies in meeting changing exhibition needs.

The Proposed Design

This project proposes a solution to address the challenges of custom book stands by integrating 3D printing and in-house fabrication. Modular cradle components will be 3D printed to ensure flexibility and scalability, while custom acrylic holders for varying book dimensions will be produced in-house using laser cutting. This approach minimizes reliance on external suppliers, reduces waste, lowers costs, and streamlines production.

PRoject Details

Development Phases

Phase 1 

Design and Prototyping ( 3 Weeks)

Phase 2

Final design and Production (3 weeks)

Materials

3D printed ABS

Stainless steel hardware

Industrial Springs

Acrylic panels

Stake Holders

Asian Civialization Museum

Project Budget

S$4700

Design Considerations

This section outlines the key project requirements aimed at reducing dependency on external resources and enhancing in-house responsiveness. The goal is to establish a streamlined process that facilitates rapid prototyping and production, particularly in response to changes in exhibitions.

Previously, the creation of book cradles relied on external vendors whenever display changes were needed. The proposed workflow shifts the focus to in-house production, streamlining the process to save time and reduce costs. By removing the need for vendor coordination—a process that often takes one to two weeks for quotes and production—projects can be completed more efficiently. This approach enables faster turnaround times for new designs, allowing for easier customisation to accommodate various book sizes. Quick prototyping and seamless design adjustments help address issues promptly. Collaboration among designers, engineers, and production staff fosters real-time idea sharing and improvements. With well-maintained tools like laser cutters and 3D printers, production remains reliable and uninterrupted, ensuring consistent and high-quality results.

The hardware used in this design consists of commonly available components that can be purchased from various shopping platforms. This accessibility makes it straightforward to source replacement parts, ensuring minimal downtime in case of wear and tear. Additionally, using standard hardware simplifies the design process, as the components are readily available and do not require custom fabrication or specialized ordering from vendors.

Because most of the hardware is standardized, there is no need to maintain a large inventory of varied components, significantly reducing the need for extensive storage space. This streamlined approach not only enhances operational efficiency but also aligns with the overarching goal of simplifying production and minimizing reliance on external suppliers. By standardizing the hardware, the workflow becomes more organized, cost-effective, and scalable for future projects.

The material used for this book stand design is PETG, which can be printed using in-house printers. This allows for greater flexibility in making adjustments to specific parts of the design without the need to engage external vendors. This capability is highly beneficial, as a request can be made in the morning, and the finished product can be printed and ready by the evening. The primary reason for selecting PETG is that, unlike ABS, it does not produce films during printing, making it more efficient and cleaner to work with.

Additionally, PLA was not chosen due to its structural weaknesses, as it is too fragile for equipment requiring durability. PETG, on the other hand, offers significantly higher tensile strength and is mechanically stronger than PLA, making it a more suitable material for this application.

Version Control

This version control of this project will focus on refining slider implementations to create a smoother, more intuitive interface that users can master within 10 minutes. Iterations will prioritize precise, controlled adjustments over free-range options, offering a structured approach to modifying bookstand parameters.

Cradle TabV1 BG

01

 

Tightening & Loosening Knob

The knobs tighten when turned clockwise and loosen when turned counterclockwise. Additionally, all knobs are identical in size and function uniformly across the design, ensuring users can interact with them consistently.

02

 

Swivel Mechanism One

This swivel mechanism controls the tilt of the book, enabling users to adjust its angle for a more comfortable reading position. By modifying the tilt, users can also minimize glare, improve visibility, and achieve the most ergonomic viewing angle.

03

Swivel Mechanism Two

This axis controls the angle at which the books are held, allowing users to adjust the position for optimal visibility and comfort. By adjusting this axis, users can set the book at the most convenient angle for reading or viewing.

04

Variable Height Mechanism

This swivel mechanism controls the height at which the bookstand can be raised, allowing for easy customization to suit the user’s preference. To adjust the height, users simply need to loosen and tighten the knobs located beside the mechanism, ensuring a secure and stable position to a desired height.

05

 

Book Cradle And Attachment

This cradle is adjustable to fit various book sizes, ranging from B4 to A3. The attachments are made of acrylic, and users can customize the acrylic to suit their preferred size.

06

Variable Width Sliders

This mechanism can be adjusted to accommodate different book sizes, allowing users to customize the position for optimal support and stability. The adjustment ensures that the bookstand can securely hold books of various dimensions.

Materials

3D Printed ABS

Stainless Steel Hardware

Nylon Ball Bearings

Dimensions

273mm (Width)

395mm (Length)

295mm (Height)

Development Time

3 weeks 

Design Goal

This initial iteration focuses on ensuring functionality before refining material, size, and design optimization. ABS has been used for all 3D printed components to reduce infill and minimize waste. 

Cradle Tab V2 BG

01

Swivel Mechanism One

The feedback regarding this mechanism highlights that it is perceived as too bulky. The goal is to reduce the size of the mechanism, ensuring it retains its functionality while minimizing its volumetric footprint.

02

Tightening & Loosening Knob

The feedback regarding this feature indicates that while it is functional, its bulkiness is a concern. This added bulk extends to other components as well. A potential improvement would be to replace the current knob with a bolt mechanism that allows for tightening and loosening, thereby reducing the overall size and enhancing efficiency.

03

Swivel Mechanism Two

The feedback regarding this mechanism highlights that it is perceived as too bulky. The goal is to reduce the size of the mechanism, ensuring it retains its functionality while minimizing its volumetric footprint.

04

Variable Height Mechanism

The feedback for this feature suggests that setting a specific height for the mechanism could allow it to be removed, thereby reducing the volumetric footprint of the design.

05

Book Cradle And Attachment

The feedback for this feature acknowledges its value, but notes that its bulky design contributes to an overall oversized appearance of the book cradle. A more streamlined design for this feature is recommended to enhance both the functionality and the overall compactness of the cradle.

06

Variable Width Sliders

The feedback for this feature suggests exploring options to anchor it to a fixed size. It is recommended to use brass or flat materials to provide quick and durable protection, rather than repeatedly reprinting parts to accommodate varying book sizes.

Materials

3D Printed ABS

Stainless Steel Hardware

Nylon Ball Bearings

Acrylic Plates

Industrial Springs

Dimensions

225mm (Width)

250mm (Length)

218mm (Height)

Development Time

2 weeks 

Design Goal

This design iteration focuses on reducing the overall volume while preserving all functions. Additionally, certain features are made with acrylic to allow in-house customization of parts, aligning with the requirements of the initial purpose.

Cradle Tab V3 BG

01

Book Cradle Attachment

In this version of the cradle, the design has been streamlined to be more compact. It now only requires four bolts to securely attach the acrylic components to the base. This simplified assembly process reduces the overall size and improves ease of installation.

02

 

Rotating Attachment Mechanism

In this final version, the feature is designed to be highly compact, requiring only four attachment points to secure the book cradle. To adjust the feature, tighten or loosen the bolts at the center of the axis rotation to modify the angle of the cradle. The mechanism allows for 360-degree rotation, with a total of 12 steps, offering a 30-degree increment for each step.

03

Variable Width Mechanism

In this design, the variable width feature no longer slides, as compared to the designs in previous versions. Instead, users can adjust the width by adding additional 3D-printed pieces to extend the cradle to the desired width.

04

Dual Axis Mechanism

Based on previous feedback and iterations, this feature combines a primary rotating axis to adjust the angle of the book cradle, along with a secondary rotating axis, which also serves as the lever mechanism for finer adjustments. The lever mechanism allows users to shift the center of gravity relative to the main axis of rotation, providing greater control over the cradle’s positioning. Additionally, the secondary axis enables precise control over smaller details and angles, ensuring a more customizable experience for users.

05

Wall Attachment Mount

To mount the book cradle on the wall, the existing feature is removed, and the middle section is attached to two brass rods, which are then fixed to the wall.

06

Acrylic Book Stand

This acrylic book stands can be replaced with a similar or taller version to increase the overall height of the stand. A key feature of this acrylic design is that it can be easily fabricated in-house using just a laser cutter. With no bends in the design, it simplifies the fabrication process.

Materials

PETG – Glass fiber (3D Printed)

Stainless steel Hardware

Acrylic Plates

Industrial Springs

Dimensions

200mm (Width)

184mm (Length)

160mm (Height)

Development Time

1 weeks 

Design Goals

This version of the book cradle features a compact design, roughly 1/6 the size of Version 2, addressing feedback about bulkiness. The holder is nearly invisible when books are placed, achieving a key design goal. All 3D printed parts are PETG-Glass Fiber and they can be printed in-house without vendor involvement.

Cradle Tab V4 BG

01

Book Cradle Attachment

In this updated cradle design, the acrylic thickness is reduced to 6mm, addressing feedback from version 3, where 8mm was too heavy and caused parts to shift downward. The design now uses sunken bolts instead of regular hex head bolts. Sunken bolts require less thickness, enabling a lighter structure. This reduction in both thickness and weight helps minimize the mechanical load on the cradle.

02


Rotating Attachment Mechanism

In this final version, the feature is designed to be assembled using M4 bolts instead of the previous M3 bolts. The M4 bolts provide a stronger grip for the rotating attachments, enhancing the mechanical stability without altering the outer dimensions of the design.

03

Dual Axis Mechanism

The switch from M3 to M4 bolts has resulted in a significant improvement in this version. In version 3, the M3 bolts had less bite strength, causing misalignment of parts when load was applied. This misalignment propagated to other parts, leading to a shift in the overall design. While each step was intended to be 30 degrees, the misalignment caused a shift of 33-35 degrees, reducing mechanical accuracy and potentially impacting planning during curation.

04


Variable Width Mechanism

Similar to other parts, the M4 bolts have had a significant impact on these components, as they now maintain their positioning much more effectively compared to version 3. This improvement is also due to a new design feature that aligns the two parts together. With the addition of the M4 bolts, the design is securely held in place, ensuring greater stability and accuracy.

05

Acrylic Book Stand

This acrylic book stand can be replaced with a similar or taller version to increase the overall height of the stand. A key update in this feature is the use of M4 bolts, which have been implemented throughout the latest design for improved strength and stability.

06

Wall Attachment Mount

To mount the book cradle on the wall, the existing feature is removed, and the middle section is attached to two brass rods, which are then fixed to the wall.

07

Interchangeable Parts for Compactness

This new feature, introduced in the latest version, allows for a more compact design. In exhibition settings, where minimal visibility of the stand is desired, this feature enables the cradle to be interchanged with an alternate design, further reducing its form factor. It is particularly useful when books need to be positioned in a more upward-facing orientation.

Materials

PETG – Glass fiber (3D Printed)

Stainless steel Hardware

Acrylic Plates

Industrial Springs

Dimensions

200mm (Width)

184mm (Length)

160mm (Height)

Development Time

1 week

Design Goals

In this final version of the cradle design, all hardware has been upgraded to M4 stainless steel bolts due to significant shifting observed in Version 3 when load was applied. This design change indicates the necessity of using at least M4 bolts for future physical prototypes. M4 bolts have approximately 1.78 times the shear strength of M3 bolts, providing greater resistance to biting and shear forces before failure.

Components List

This section provides a detailed list of all components in the final design, including parts, hardware, quantities, materials, and 3D printing settings. It will documents the source, supplier, specifications of each item, and relevant details on material properties and optimal 3D printing parameters.

P01 (x1)

P02 (x1)

P03 (x1)

P04 (x1)

P05 (x4)

P06 (x2)

P07 (x2)

P08 (x4)

P09 (x1)

Print Settings

Layer Height: 0.2

Wall Loops: 6

Top Layer: 6

Bottom Layer: 6

Advance Settings

Order of Walls:

Inner/Outer/Inner

Infill: 40%

Infill pattern: Gyriod

Temperature Settings

Nozzle: 250-260°

Bed: 70-80°

Total Print Time

18-20 Hours (Approximately)

Materials

PETG – Glass fiber

Stainless Steel Bolts

M4, 22mm (x8)

M4, 28mm (x2)

M4, 30mm (x10)

M4, 65mm (x12)

Stainless Steel Inserts

M4 x M8 x 6mm (x14)

M4 x M8 x 12mm (x12)

(ID x OD x H)

Industrial Springs

M5 x M8 x 10mm (x4)

(ID x OD x H)

Nylon Washers

M4 x M8 x 1mm (x30)

(ID x OD x H)

Assembly

This section outlines the process for assembling the final design using the 3D printed parts and hardware described earlier. It provides step-by-step instructions, specifying which parts should be embedded into the 3D printed components. Additionally, it covers the preparation of each part, including handling, fitting, and any necessary modifications to ensure a smooth and efficient assembly.

How to Prepare the Parts

This section outlines the process for inserting the stainless steel inserts into all the 3D printed parts necessary for the design assembly. It is important to complete this step before the assembly. Additionally, to ensure the stainless steel inserts remain securely embedded in the 3D printed parts, it is essential to use Maxi-Cure™ Extra Thick CA Glue for bonding plastics and metals.

How to Apply Maxi-Cure

Apply Maxi-Cure™ CA to one side of the parts to be joined, then press them firmly together for 10-20 seconds. For larger bonding surfaces, apply serpentine beads of the CA adhesive, ensuring sufficient spacing to allow for proper spreading. The adhesive will reach full strength within three hours. Clean the nozzle before securing the screw-on cap. To extend shelf life, refrigerate the product. Once cured, Maxi-Cure™ CA remains stable within a temperature range of -40°F to 220°F.

P01

M4 x M8 x 6mm (x2)

P02

M4 x M8 x 12mm (x4)

P04

M4 x M8 x 6mm (x10)

P06

M4 x M8 x 6mm (x1)

P07

M4 x M8 x 6mm (x1)

P08

M4 x M8 x 12mm (x4)

P09

M4 x M8 x 12mm (x4)

Cradle Assembly Step01

Stainless Steel Bolt ( M4 x 35mm )

Black Nylon Washer ( M4 x M8 ) 

Stainless Steel Bolt ( M4 x 30mm )

Industrial Spring ( M5 x M8 x 10mm )

Assembly Reference

Completed Assembly (Step 01)

Cradle Assembly Step 02

Nylon Washer ( M4 x M8 ) 

Stainless Steel Bolt ( M4 x 22mm )

Acrylic ( Thickness: 8mm )

Assembly Reference

Completed Assembly (Step 02)

Cradle Assembly Step 03

Nylon Washer ( M4 x M8 ) 

Industrial Spring ( M5 x M8 x 10mm )

Stainless Steel Bolt ( M4 x 35mm )

Stainless Steel Bolt ( M4 x 65mm )

Stainless Steel Bolt ( M4 x 65mm )

P02

Assembly Reference

Completed Assembly (Step 03)

Cradle Assembly Step 04

Tapered Stainless Steel Bolt

( M4 x 30mm)

Custom Acrylic Sheet

(Thickness: 6mm)

Assembly Reference

Completed Assembly (Step 04)

Cradle Assembly Step05

Stainless Steel Bolt ( M4 x 65mm)

Stainless Steel Bolt ( M4 x 65mm)

Stainless Steel Bolt ( M4 x 65mm)

Stainless Steel Bolt ( M4 x 65mm)

Industrial Spring ( M5 x M8 x 10mm)

P09 (Printed Part)

Assembly Reference

Completed Assembly (Iteration 02)

Adjustable Elements

This section outlines the various design features of the Project Cradle, which users can adjust to achieve the optimal height and angle. Additionally, it provides instructions on how to reconfigure different components as needed. Each feature is accompanied by a tutorial video, detailing the steps for use and the necessary tools.

Cradle V4.5

01

Attaching/Detaching the book cradle 

The cradle is designed to allow the production team to easily adjust its size. If a larger cradle is needed, they can laser-cut the required dimensions, bend the material accordingly, and attach it to the holder.

 

02

Changing the configuration

The configuration being referred to involves adjusting the rotatable joint that controls the tilt angle of the book cradle. The process described above illustrates how to transition from a stand with a high tilt angle to one with a lower tilt angle.

03

 

Attachment to wall

To convert the stand into a wall-mounted setup, first, remove the two screws from the base attachment points. However, the rods mounted on the wall must be installed first before securing the base in place.

Cradle V4.4

04

Dual Swivel Mechanism

This feature allows the user to align the board at the center of the rotation mechanism and secure it in place. Once the desired angle is achieved, the user can tighten it to hold the position. The design includes two rotating mechanisms to provide additional degrees of rotation if required.

05

Cradle Swivel Mechanism

This feature enables the user to adjust the swivel angle of the book cradle for optimal positioning.

Project Timeline

This section provides an overview of the key development goals, along with comments and feedback for each version, highlighting the improvements made from previous iterations.

Design Ver.1

Phase One

Phase one centered on testing functionalities to achieve a practical design. This included building the book cradle to verify angles, adjusting mechanism heights to find the best fit, and evaluating swivel mechanisms to assess necessary customizations. The goal was to explore all options before refining the design.

Phase One

Design for Functionality

Design Ver.2

Phase Two

In phase two, the focus is on reducing the design's form factor. The variable width mechanism was changed from a parallel to a perpendicular design, improving strength and stability to prevent wobbling. Additionally, alternative materials are being explored, with a shift from ABS to PETG planned for the next iteration.

Phase Two

Design for Stability

Design Ver.3

Phase Three

Phase three aims to significantly reduce the form factor. Bulky knobs were replaced with M3 bolts, cutting the design’s volume to one-fifth of the previous version. The cradle’s stand was also redesigned to have four contact points instead of a full base, streamlining the overall structure.

Phase Three

Reducing Form Factor

Final Design Ver.

Phase Four

Phase four focuses on standardising all parts to use M4 bolts instead of M3, addressing feedback about joint torsion when a book is placed on the cradle. Additionally, slots were added to the 3D-printed parts to prevent sliding or torsion under heavier loads, improving overall stability.

Phase Four

Design for Optimization