In this assignment, I redesigned a Harbor Freight electric screwdriver, with an emphasis on improved product styling.

I began by making a large number of sketches to explore possibilities.

From these, I made a model from automotive clay to start working in actual size. Though not visible, there is a mockup of the screwdriver components inside the clay, made out of various sizes of dowels.

With the physical understanding gained from the clay model, I made my first CAD model in Autodesk Fusion 360. While the overall style was pretty close to what I wanted it also had room for improvement. Mainly, the handle was weirdly faceted,

I made my first 3D print from this design. While I tried to include the supports, ribs, and bosses on the inside, the measurements were off. I kept that in mind as I refined the CAD model.

The trigger area was still unresolved, but the handle flowed better and joined the main body more naturally. I then achieved my final CAD model.

I extended the upper front of the handle so that it would properly cover the switch and supports for the trigger.

I used fused deposition modeling to 3D print a test model of this shell to ensure everything fit (not shown,) then made the final shell with stereolithography 3D printing, which is more exact and finer quality. The components fit perfectly so I began sanding to prepare this shell for painting.