Final Design Report: https://drive.google.com/file/d/1MWmWVFvpB9gdffdAA-bLkPCJ42nuv5V0/view?usp=sharing

Background

For the course ME 110 Product Development in Spring 2023, I was challenged to develop a product with a strong market fit and conduct research and early-stage prototyping for the product. Our project was initiated to develop a product aimed at enhancing the card game experience for casual and serious gamers alike. The card game market, valued at $13.7 billion in 2022 and projected to reach $21.4 billion by 2023, presents significant growth opportunities. However, the existing market is predominantly focused on professional settings, leaving a gap for products tailored to casual settings.

Problem

The main challenges identified include the time-consuming nature of shuffling and distributing cards, the potential for players to cheat during dealing, and the inconsistent shuffling abilities of different players. The goal was to create a product that addresses these issues, making card games more enjoyable and stress-free for all participants.

Solution

My team developed "CARDO," an automatic card shuffler and dealer, through a comprehensive design, prototyping, and programming process. Our approach focused on efficiency, speed, ease of use, and affordability.

Key results and impacts include:

Design and Development:
- SolidWorks Solid Modeling: The product was designed using SolidWorks, enabling precise and detailed solid modeling of each component.
- Shuffling Mechanism: Developed an effective shuffling mechanism using aggregator gears and rubber gears, pushing the cards toward a central shoot to ensure thorough mixing.
- Distribution System: Designed a system where cards slide down an incline and are propelled by central rubber rollers, with a rotating base facilitating even distribution.
- User Interface: Implemented a simple one-button UI, making the device extremely easy to use for people of all ages and tech-savviness.
Prototyping:
- 3D Printing: Several iterations of the design were 3D printed using PLA. This iterative approach allowed us to test and refine the mechanical components rapidly, ensuring optimal performance and durability.
- Laser Cutting: Made prototypes out of acrylic using laser cutting techniques, providing a clear and precise structure for parts that required high accuracy.
- Component Selection: Chose DC motors with optimal speed and torque output, essential for the smooth operation of the shuffling and dealing mechanisms.
- Control System: Utilized an ESP-32 microcontroller to control the DC motors, ensuring reliable and efficient operation of the shuffling and dealing processes.
Assembly and Programming:
- Integration: Assembled the prototypes meticulously, integrating the 3D printed and laser-cut components with the electronic parts.
- Programming: Programmed the ESP-32 microcontroller to handle the motor controls and the user interface, ensuring the device operated seamlessly. The programming included routines for shuffling and dealing cards quickly and accurately.
Testing and Validation:
- Performance Metrics: Evaluated the prototypes based on shuffling speed, distribution speed, ease of use, portability, and ease of manufacturing. The final concept, "AB1," scored highest in these areas.
- Customer Feedback: Conducted user testing, receiving positive reviews highlighting the product's efficiency, ease of use, and high-quality construction.
Customer-Centric Design:
- Affordability: Set a retail price of $29.99, with a manufacturing cost of $20, making the product accessible to a broad audience.
- Refinement: Incorporated feedback from initial testing to refine the product, enhancing features such as speed and ease of use.

Conclusion:

Through careful design in SolidWorks, iterative prototyping with 3D printing and laser cutting, precise selection and control of DC motors using an ESP-32, and user-centric programming, CARDO was developed into a functional and reliable device. The final product addresses the identified challenges, making card games more enjoyable and stress-free. Supported by a robust business model and positive customer feedback, CARDO fills the market gap for casual card game enthusiasts.

Card Shuffling Robot - "Cardo"