After finishing the sketch of the battery holder with the dovetail edges and the hinges, my partner and I tested out the battery holder design on 1/8'' delrin.
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| The bottom broke off and these sides are nearly impossible to snap together at the corner. |
We identified a major problem with our idea; sides with dovetail edges and a bottom with hinges do not work well together. The hinges that make the sides bend from the bottom kept breaking because the dovetail edges do not connect at right angles. You must connect the sides like a puzzle first and then fold them to make a corner. Hence, we needed a new idea. I came up with a new way to make the lantern that incorporated both the hinges and dovetails (image shown below).
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| This is our model for the battery holder and the lantern case on 1/8'' wood. |
Instead of making a lantern in the shape of a box, it will be an oval. The wooden hinges will stretch when we place the batteries inside. The pressure from the batteries on the hinges will make the dovetail pieces stay closed.
Our professor gave us the idea of making a simple oval with tabs sticking out to make the bottom of the battery holder.
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| Using the battery dimensions, we sketched out an oval that would fit properly. |
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| Completed battery holder! |
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