The Air

Droplet

Design and Prototyping Process

  • Prototyping

    Moldable wax was used to create a proof-of-concept model. Form was then explored in Autodesk Fusion, printed in Rigid 4K resin and scaled to meet stock requirements.

  • Manufacturing plan

    Whistle body was positioned within stock to allow cavity to be machined precisely.

  • CAD Model

    CAD Model

    The final design was modeled in Autodesk Fusion and translated into CAM. The fipple was designed for manufacturing on a manual mill/lathe.

  • Initial concept sketches

    Ideation began with a collection of sketches. Functionality and organic form were chiefly important throughout my initial design process.

Manufacturing & Assembly

Outside of squaring stock and facing wax, the air droplet required three manufacturing setups.

Front Pocket

Whistle Cavity

The fipple was made on the manual mill/lathe and the whistle was assembled using an arbor press.

Back Pocket