Situation

As part of a rapid prototyping course, our team assisted an environmental science professor who needed to measure airborne pollutants from specific wind directions. For example, the research might require recording hydrogen sulfide levels only when the wind was coming from the north, allowing the professor to better identify the location of a potential emission source.

The air sensor therefore needed a physical cover that could respond to wind-direction data and control when the sensor was exposed. Because the device would operate outdoors, it also needed to withstand rain, dust, wildlife interference, and repeated use.

Task

My task was to design and build a reliable cover mechanism that could integrate with a wind-direction sensor. The device needed to be:

Robust enough for outdoor deployment.
Reliable during repeated movement.
Resistant to weather and animal interference.
Affordable to manufacture.
Easy to assemble, install, and maintain.

Action

I began by building proof-of-concept prototypes from PVC pipe. These early models allowed me to quickly test the core geometry and validate whether a physical cover could effectively control the sensor’s exposure.

After confirming the concept, I developed several 3D-printed iterations. Each version was evaluated for fit, motion, structural strength, environmental protection, and ease of assembly. Feedback from each physical test was immediately incorporated into the next CAD revision.

I eventually simplified the mechanism into a direct-drive design. Reducing the number of moving parts improved reliability, lowered manufacturing complexity, and made maintenance easier. The final enclosure was designed for straightforward assembly and component access, with a printing cost of approximately $3 per unit.

I also refined the enclosure interfaces and geometry to improve sealing and protect the internal sensor from water, dust, and interference from animals.

Result

The final device achieved an independently tested IP55 rating, demonstrating resistance to dust and water exposure in an outdoor environment.

Its direct-drive architecture delivered reliable operation with minimal mechanical complexity, while the 3D-printed construction kept manufacturing costs low and made replacement parts easy to produce.

During the final class evaluation, the RCD device ranked first for robustness and reliability. The project demonstrated how rapid prototyping and mechanical simplification could turn a specialized environmental research requirement into a practical, field-ready solution.

Wind-Directed Air Sampling Device