Design and Prototyping of a Waterproof Probe Enclosure

Sammanfattning: This 30 credits master thesis was a project which marked the last part of the Industrial Design Engineering masters' program at Royal Institute of Technology (KTH), Stockholm. The thesis was conducted at Alten Sverige in Kista, Stockholm during spring 2015. The report describes a product development project with the aim of developing and producing a prototype for a waterproof enclosure of a probe which has high demands on sealing capability as well as durability against other externalinterference such as vibrations, impacts and weather. A theoretical study was made in the beginning of the project within the fields of seal design, eco-design, materials and manufacturing. The study led to deeper knowledgein the areas and formed a base for the development. The product and its use was mapped and design requirements for the enclosure were determined. Several design concepts were developed, both from the point of aesthetics and different functions using methods such as brainstorming, 6-3-5 Brainwriting, Build To Think and amorphological matrix. The concepts were evaluated and selected by using a decision making matrix. A final concept was selected and developed further, which resultedin a hamburger structured enclosure with an o-ring sealing. The probe is attached to the target object by using mounting tape. A concept for a snap-fit attachment was also developed. In order to find the most suitable process and material for the final prototype several rapid prototyping processes and materials were tested. The iterative prototype process was a key part of the development of the concept. The final prototype consists of a rotational milled base part with a vacuum formed cover. 3D printed tests for the snap-fit attachment was made. Different test cases and real life scenarios were put forward and provided basis for the testing and evaluation of the prototype. As the tests showed mainly positive results, the project was successfully conducted.