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2010 Design for Direct Digital Manufacturing Competition Winners

First Place
 Remote Rechargeable Universal Remote (PDF)
Palmer Hawkins, Heather Wampler, David Ricsi, Brett Christensen, Jared Wilcock and Curtis Carrigan, Mechanical and Aerospace Engineering Department, Utah State University, Logan, Utah

Synopsis: This custom, rechargeable, universal remote was designed to appeal to those in or just graduating from college. The vision behind this unique design was a remote that was made to fit each school, and the mass customization needed for this project makes it an ideal fit for DDM.
Second Place
Sensor Wireless Moisture Sensor Unit for Automatic Sprinkler Systems (PDF)
Corey Staley, Jim King, Andrew Decuester and Andrew Felix, Mechanical and Aerospace Department, Utah State University, Logan, Utah

Synopsis: This wireless soil/lawn moisture sensor would control the on and off operations for an automatic sprinkler system. Individual sensors would be placed in the soil layer, just beneath the surface of the vegetation or soil to avoid accidental breakage from mowers and children, and would measure the moisture content, which in turn will control the sprinklers for their respective zones. The wireless capability of the sensor would allow it to be placed anywhere and not just along the edge of the zone. The sensor units will send a message to the control board specifying when and if a particular zone needs water based on a certain moisture threshold.
Third Place
Showerhead The Unequivocally Green Shower Head (PDF)
Breck Byington, Ben Griffiths, Michael Keck, Chelsea Lechtenberg, Leron Lechtenberg and Derrick Pate, Utah State University, Logan, Utah

Synopsis: The most significant benefit obtained from this showerhead design is that it is uniquely shaped and can be customized, which allows the customer to have a unique product not offered anywhere else on the market. The customer will also be able to make decisions about the color and surface finish of the final product. Traditional plastic injection molding would require a multistage process and would still be incapable of producing a showerhead that exactly resembles our design. There would also be a need for the molded parts to be assembled into the final product. DDM would allow the showerhead to be manufactured in one step.
The Task

The student designers were encouraged to use their imagination to design a product intended for household use that has unique direct digital manufacturing (DDM) features. The product had to be used in the home and had to have a minimum impact on the environment. It also had to be fabricated mainly using DDM processes. Following were the design criteria for the competition:

  • The item will be for residential use (i.e., home or apartment).
  • The design should represent a fully working prototype. Any internal electronics or mechanics must be specified within the design.
  • The geometry of the design must be defined within a 3D, computer-aided design (CAD) system capable of producing robust STL files.

To learn more about the annual DDM Competition, click here.