This is something I challenged myself with in my spare time to practice advanced assembly techniques.

It was a trick to make the spokes line up and cross over each other. The spokes required a point to surface constraint.

 

 

Modeled in WF2.0, this cost reduction project assumed that a better product could be made by qualifying the most optimal suppliers.

There are nearly 100 discrete parts in the assembly not including the parts in the subassembly for the castors.

 

 

The entire assembly.

 

 

Modeled in WF2.0, this is the new ergo blister pack.

No ISDX was used on this model, however, some light surfacing was. Shell thickness is .05"

Modeled in WF2.0, this battery pack is rechargeable and serviceable. It fits in a bicycle water bottle profile.

The working model is rated for 50 Watt/Hours and can handle a 30 Watt load. It charges within 2.5 hours.

The clear tube is for wiring.

 

Here is a physical model with a negative temperature coefficient (NTC) thermister to shut off the smart charger at 50 to 55 degrees centigrade. It also has a 10 amp PTC fuse.

Each Anderson connector is identical to one another. Red stays positive and black stays negative with no plugs and sockets to keep track of.