CAD software used - Fusion 360
Manufactured - 3D Printed
I have had an empty door knob on my door for about a year and decided to utilize my knowledge of CAD and my 3D printer to make a new door knob that would allow me to shut my door.
I was unsure how a mechanical door knob worked from the inside, but I knew it turned a rotation input into a horizontal translation output along a straight line.
I started with the designing of the rod first as I needed to make a design that moved left and right with a circulation movement from the knob. These are some of the designs I first made.
These first designs were not successful as it not only did not fit in the slot of the door frame where the rod goes but it also did not achieve the horizontal translation movement I needed.
I then came up with this design that would fit the cylinder from the door knobs tighter and I added a cut to the top so it would fit into the door frame slot.
I then began to work on the door knobs which were easier and only required one print because I had a good idea of what I wanted to make.
I decided to print 2 separate knobs one with a cylinder sticking out and one with a hole on the top that would fit this cylinder.
I also needed something to support it when it would sit normally or if it was being pushed or pulled.
I solved this by making two disks of 2 different sizes, one would be glued with acrylic to the cylinder on the knobs (plastic on plastic) and the other would be hot glued to the actual door (wood on plastic)
The smaller disks that were glued to the door knob would resist any push and pull forces as they were placed on the outsides of the bigger disks and when put together, it acted as a clamp to the door. The bigger disks were glued to the actual door and allowed the cylinders of the knobs to stay in place.
After designing all the parts I put them together in an assembly in Fusion and used motion link to make sure the mechanical movement I had imagined would actually work and it did.
The door knob allowed about 4 inches of movement total left and right and was achieved with one 90 degree turn which was my goal.
This was the final product after gluing and printing everything. I decided to add a rubber band that would loop around the backside of the rod so there was a small force when turning the knob allowing it to lock automatically when the door was closed. This could have also been achieved by designing the rod to fit a small spring on the back and also drilling a small hole on the inside of the door to hold the spring.
Some things I took away from this project was how different glues are better for different materials which is why I used hot glue and acrylic glue and also when designing something that will be 3D printed you cannot just design whatever you want you need to follow some rules like making sure there is some flat surface on your design where the print will start and work up from and also to not have any overhangs. Overall the project was fun and I did not encounter any issues I couldn't figure out.