CASE STUDY
ARC Homogenizer Sound Proof Box
Overview
The Ultrasonic Homogenizer located in the ARC bio-laboratory produced an extremely high-pitched, disruptive noise—comparable to fingernails on a chalkboard—during operation. This sound propagated through adjacent laboratories and into the hallway, creating a significant disturbance. The Makerspace team was assigned the task of designing and constructing a soundproof enclosure to mitigate this issue.
Design Concept
To address the high-frequency noise, I conducted research into effective soundproofing materials. I identified Mass Loaded Vinyl (MLV) as a particularly suitable option due to its high density and excellent sound-dampening properties, especially for high-frequency acoustic energy.
Construction Process
The enclosure was constructed from ½-inch laser-cut plywood, designed to fully encase the Homogenizer. To prevent vibration transmission, isolation feet were installed at the base. Stainless steel hinges and latches were used to ensure secure and functional access to the interior.
The interior of the box was lined with Mass Loaded Vinyl, applied using contact cement. Seams were overlapped to prevent sound leakage, and the door was also fully covered with MLV. All joints were sealed with a sound barrier adhesive silicone to ensure airtightness.
To further enhance acoustic insulation, a second layer consisting of 1-inch thick acoustic foam panels was added. These panels were adhered to all interior surfaces, including the door, to absorb residual vibrations and high-frequency noise. Finally, foam insulation tape was applied along the door edges to create a tight seal when closed.
Results
The completed soundproof enclosure effectively eliminated all audible noise produced by the Homogenizer. When the device operated within the enclosure, no sound was detectable from outside the box, confirming the success of the design and construction.
CASE STUDY
ARC Vessel Holder For Homogenizer
Overview
In the ARC bio-laboratory, the Ultrasonic Homogenizer previously required users to manually hold small beakers and vessels during operation. However, with the recent implementation of a soundproof enclosure (see previous case study), manual access was no longer feasible due to the sealed design of the box. As a result, the Makerspace team was tasked with developing a secure and adaptable vessel-holding solution that could function within the enclosure.
Design Concept
Initial research explored the feasibility of using adjustable mechanical arms to grip various vessel sizes. However, this approach proved overly complex and unreliable in terms of achieving a consistent, secure grip across different geometries. Instead, a simpler and more robust solution was proposed: a modular holder system using interchangeable plugs tailored to specific vessel dimensions.
Design and Fabrication
The final design featured a solid base 3D printed in PLA, chosen for its rigidity and ease of fabrication. Isolation feet were added to the base to minimize vibration transmission and ensure stability during operation. Custom plugs were then designed for each vessel size and printed using flexible TPU 95A filament. This material provided the necessary elasticity to securely grip vessels while allowing for easy insertion and removal.
The combination of a heavy, stable base and flexible, form-fitting plugs ensured a snug fit for each vessel, effectively eliminating movement and vibration during homogenization.
Results
The completed vessel holder met all functional requirements and passed laboratory testing. It provided a reliable, hands-free solution for securing various vessel sizes within the soundproof enclosure, significantly improving usability and safety during homogenizer operation.
CASE STUDY
Repairing Broken LED Photo Lights
Overview
My LED photo lights were functioning well; however, the sections where they connect to the tripod top/holder were broken on both sides of two different lights. Without these holders, the lights became nearly useless for illuminating areas or objects during photo shoots.
Options Considered
I faced two choices: either purchase entirely new lamps and discard the broken ones or design and fabricate replacement parts for the lights. I opted for the latter.
Design and Measurement
To create the replacement parts, I utilized Autodesk Fusion for design and a caliper for precise measurements. The components are intricate and require accuracy, as each side has three small bolts and two larger insert nuts for attachment to the tripod mount. Additionally, there are three pins on each end that help align the part within the lamp. One side also necessitates a slot for the plexiglass diffuser to easily slide in and out.
Printing Process
I employed the Bambu Carbon X1 3D printer and used black PETG filament to print the new parts. To install the original brass insert nuts, I utilized our new Insert Heat Press, ensuring a secure fit.
Design Modifications
In the design phase, I made adjustments to simplify the components and enhance their strength. I reduced the number of pins needed to secure the sliding diffuser to just two.
Results
The final outcome was outstanding; I successfully restored both photo lights to like-new condition, ready for use in future shoots.
