The Electric Vehicle Charger project starts with understanding the function and internal components of an existing charging handle.
This project is the crown jewel of the semester. Students design an EV handle that incorporates existing parts (SAE J1772 connector). Based on a chosen brand the design embodies characteristics of a visual brand language. The students go through a multi-week design process from an inspiration board to sketches to hand carved foam models. Human factors of hands are emphasized. Then the final foam model is used to create templates, which are translated into CAD to drive the surface design. That revised design is then CNC-milled in two halves for evaluation. This is a great teaching moment: Is the CAD design holding up to the promise of the hand carved model and the overall concept? Finally, time is dedicated to rebuild the CAD model and to add manufacturing details for a 3D print with part lines, mounting bosses and fitting internal parts such as the SAE J1772.