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Project 5 Stage 2 prototype cover

Design Project #5 Stage 2 — Prototyping and Testing

A visual record of four prototype cycles, documenting how the design changed through CAD, CAM, and material iteration.

Iteration CAD CAM Material Testing Assistive Design
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Project Overview

This page is a picture-based record of Stage 2 of Design Project #5. It focuses on how the prototype changed across four cycles of iteration: making the first version, changing the shape in CAD, changing the machine settings in CAM, and finally changing the material. Each photo documents a different step in the design process, showing how testing and fabrication decisions shaped the final prototype.

Iteration Cycles

Cycle 1 — First Prototype

Cycle 1 first prototype

Initial prototype printed in PLA to test the first concept and basic fit.

Testing the first version to identify major structural and usability issues.

Cycle 2 — CAD Redesign

Cycle 2 redesigned geometry

Updated CAD geometry after learning from the first prototype.

Second prototype showing shape changes intended to improve performance.

Cycle 3 — CAM Redesign

Cycle 3 print settings iteration

Third prototype with slicing and machine-setting changes to improve print quality and strength.

Testing the CAM-adjusted version to evaluate whether print settings improved reliability.

Cycle 4 — Material Change

Cycle 4 new material prototype

Fourth prototype using a different material to improve flexibility, durability, or comfort.

Final round of testing to compare the material change against earlier versions.

Prototype image 1
Prototype development photo from Stage 2.
Prototype image 2
Testing setup or fabrication detail.
Prototype image 3
Visual comparison between different iterations.
Prototype image 4
Close-up of a key design feature or print result.

Quick Facts

Course: ENGR11

Project: Design Project #5 Stage 2

Focus: Prototyping and Testing

Method: 4 cycles of iteration

Workflow: CAD → CAM → Material → Testing

Cycle Structure

• Cycle 1: Make something

• Cycle 2: Change the shape

• Cycle 3: Change the machine settings

• Cycle 4: Change the material

What to Show in Photos

• CAD screenshots

• Printed prototypes

• Testing setup

• Comparison shots between cycles

• Final improved version