Embedded Files
RoleProcess DesignerRapid PrototyperProgrammer
Duration2021 - 2022
Initial Question
Initial Question
Is it possible to inject electric circuits into mattresses or desk chairs?
Here I show how I built a tool to inject wires into soft foam.
Technology
Technology
Wire Injection in a nutshell
Wire Injection in a nutshell
Similar to a sewing machine, loops of cable are pushed into the soft foam with a sharp canula.
Prototypes
Prototypes
Building a Wire Injector in three iterations
Building a Wire Injector in three iterations
Version 1 transported wire with a filament extruder, commonly used in 3D-printers. The blade in the front was connected to a powerful gear box in the back of the tool. Due to the large size and over-complicated construction, I decided to redesign the whole prototype.
Version 2 introduced a powerful lever-mechanism for cutting. I designed a new, 3D-printed extruder with an integrated wire sensor.
For the final version, I discarded every feature that was not absolutely essential. I ended up with a small device to transport and inject wire into foam - extremely reliable and light weight.
Controller
Controller
The "translator" between the robot and the injector tool.
The "translator" between the robot and the injector tool.
The robot told the injector when to transport wire or when to cut. The controller's job was to translate from robot signals into motor speeds.
I designed, soldered and programmed the control board from scratch.
Learnings
Learnings
What would I do different next time?
What would I do different next time?
I would start with simple prototypes and advance to more complex designs.
I would not try to solve all requirements in the first approach.
Gain feedback on design flaws early.
Wire injection works in principle. In the future it could be transferred to other applications, like the integration of sensors in soft foam.
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