3/16/20 - 5/23/21
Initial Idea – Latest Product Developed
A close friend and I set out to create a small startup with our target market being historical reenactment hobbyists. In this hobby, individuals reenact wars, battles, or times of history. We set out to make replicas of items that were protected from wear in this hobby, or otherwise difficult to obtain.
I was primarily responsible for the design and production of the items, while my friend sold them. We imported manufacturer catalogs originally used during WW1 and remade the items we expected a demand for. I broadened my skills in Fusion 360, AutoCAD, Material Selection, DXF file preparation, and FDM and SLA 3D Printing. I also worked with local Pittsburgh manufacturers to cut sheet metal designs.
The buckles were one of our best sellers and were originally remade in Fusion 360. Models were then ported to AutoCAD and prepared into DXF files ready for laser cutting. We selected steel by researching weather-resistant alloys with surfaces resembling the original. I received quotes from different laser cutting businesses and chose the best offer. Pairs sold for $15, giving us a 372% ROI.
One of our services was to retrofit traditional glasses into Maskenbrille. We redesigned the frame temples (arms) in Fusion 360 and screwed it into a pre-made frame front. We then sewed on period-accurate strap loops. This gave us prescription glasses worn underneath gas masks. We originally FDM 3D printed them in PETG but have since moved to resin Stereolithography (SLA). This greatly increased the resolution and enabled batch production.
Our team worked on other products that expanded my mechanical skills. I learned sheet metal bending for crate latches, Fusion 360 design tools for modelling hat buttons, and mold design for prototyping new products.
This project started before I entered college, and was my foundation in cost accounting, manufacturing methods, and market research. This project ended due to the limited market size, making us profits only within the hundreds. We still occasionally do custom orders to preserve history and refine our production quality. I attribute studying a minor in Industrial engineering, and certificate of Innovation, Product Design, and Entrepreneurship to this project.