Overview
Role - Mechanical Designer | Product Designer | Rapid Prototyper
Tools - AutoCAD, FDM 3D Printing
Skills - Mechanical Design, Product Design, Design for Additive Manufacturing (DfAM), Design for Assembly (DFA), Rapid Prototyping, User-Centered Design, Manufacturing, Prototyping, Testing & Validation
Design Process
The objective of this project was to create a simple, always-accessible physical to-do list that eliminates the inconvenience of misplaced paper notes or digital task lists hidden within a smartphone. The design allows users to keep handwritten reminders directly on the back of their phone while remaining easily removable and compatible with other magnetic surfaces such as refrigerators, filing cabinets, or workstations.
The design consists of a three-piece 3D printed assembly that securely retains a stack of modified Post-it notes while maintaining a compact profile. A spring-loaded internal mechanism continuously applies pressure to the note stack, ensuring the remaining notes stay firmly positioned as individual sheets are removed. Standard 2" × 3" Post-it notes are created by trimming readily available 3" × 3" notes, allowing inexpensive and widely available refills.
Manufacturability was a primary design consideration throughout the project. Each printed component was designed to require no support material, reducing print time, material consumption, and post-processing. The assembly also utilizes standard off-the-shelf hardware, including M3 fasteners, hex nuts, keyboard springs, and an adhesive magnetic ring, minimizing custom components while simplifying assembly and future maintenance.
The magnetic attachment system is integrated directly into the bottom plate by embedding a magnetic ring during the printing process using a programmed layer pause. Variable layer heights were incorporated into the final print to improve the surface finish above the embedded magnet while maintaining efficient print times throughout the remainder of the component.
The product was designed for straightforward assembly using only a small number of components. Self-locating features position the springs and internal plates during assembly, while the top plate securely retains the note stack using four corner fasteners, resulting in a durable and easily serviceable product.
Results
The completed design provides a compact and practical productivity tool that keeps handwritten task lists readily accessible throughout the day. By attaching directly to a smartphone or other magnetic surfaces, the device encourages quick note-taking without requiring users to unlock their phone or carry separate paper lists.
The project successfully demonstrates the application of user-centered design principles while balancing manufacturability, assembly efficiency, and functionality. The final design minimizes printed components, eliminates the need for support material, incorporates standard hardware, and simplifies manufacturing through embedded magnet integration and support-free geometry.
This project highlights the complete product development process—from identifying an everyday usability problem through iterative mechanical design, additive manufacturing optimization, prototyping, and functional validation—to create a practical consumer product suitable for low-volume manufacturing.