Custom Caddy
A shower caddy made using additive manufacturing and generative design
This shower caddy, intended for college students to use in dorm showers, is able to hold all of the products I use in the shower as well as hang on a hook or be held in a hand with a full load of products. Made from ABS, it is able to withstand extensive water and moisture exposure.
Team:
Individual Project
Timeline:
3 Weeks
Tools/Processes:
CAD, Static Simulation, Generative Design, FDM 3D Printing
Material Analysis
I decided to make my shower caddy out of ABS because it is durable and has a high heat resistance. ABS can withstand temperatures up to about 100°C. Its heat deflection temperature is between 88-89°C and its melting point is about 200°C. Heat resistance is important because sometimes the water in the shower can get very hot. ABS is also good for waterproofing because it is not as hygroscopic as other materials, so it absorbs less moisture. Additionally, you can acetone to vapor-smooth ABS. Vapor-smoothing is a chemical process that removes layer lines and creates a smoother, sealed surface that is great for waterproofing.
Initial Generative Design
I created a CAD file with just the necessary geometry to create compartments to organize products, a handle, and a base with holes for water to go through. Then I added the obstacle geometry to represent areas that I wanted to avoid in the design.
Load Cases
I created seven different load cases to different use cases as well as improper loading conditions, such as hitting the caddy on the side or dropping it.
Initial Generative Design Results
I didn’t like the look of this result, and it was also not functional because there was no way to put some products into the caddy.
Updated Generative Design
I changed the design slightly by extending the obstacle geometries upward. Using the same load cases, I ran the algorithmic modeling again to get a new design.
Static Simulation
This load case represents a full load of products with some force applied on the upper band (10 lbforce on the base and 5 lbforce on the upper band). Although the minimum safety factor appears to be 0.431, I couldn’t find many spots on the model with a safety factor below 3 and I could not identify any red spots.
Final Design and Prototype
I added more vertical beams and one band around the outside in the middle of the top band and the base in order to keep the objects from falling out, but the structural strength of the design comes from the generative design components. Then I printed a full-size prototype out of PLA. It turned out well and performed well when I tested it so I went ahead and printed the final product.
Slicer Screenshots
I used a Gyroid infill pattern and increased the wall loops from 2 to 4 for extra strength. I used tree supports to decrease volume and printing time.
Final Product
