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EarPods
Holder
For iPhone
Fall 2018
Overview
This project was done for the final project for E27: Introduction to Manufacturing and Tolerancing at UC Berkeley in a team of five people.
About the EarPods Holder
For this project, I mainly focused on the abstract earphone model, which was the biggest challenge of the project since it was not possible to find the exact dimensions of the iPhone's EarPods. Several prototypes were printed to find the best shapes, sizes and tolerance fit.
Final Prototype - Solidworks
Design Approach for Prototyping
It was decided to have the prototype made by 3D printing since it provides a tolerance of 0.2 mm or less and it also allowed for quick prototyping. For future massive production injection molding would be a better approach for manufacturing. Below are the different fits for the lighting port and the lower housing of the EarPods in order to find a snap fit for both of them used on the final prototype.
Lighting port tolerances
Lower housing tolerances
One of the biggest design challenges was to find the perfect fit for the EarPods; therefore; many different geometries and features were used while sketching in Solidworks and it was necessary to print as many samples as needed until the correct tolerance was achieved.
Testing prototypes
Perfect fit prototype
Perfect fit prototype
Prototype
The final prototype was constituted of two parts, the iPhone case (1) and the EarPods case (2) as shown below on the exploded isometric assembly. These two parts stay together using a snap fit.
Exploded Isometric Assembly
Final Prototype:
Final prototype EarPods case - Front
Final prototype EarPods case - Back
Final Prototype
EarPods Case Drawings
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