Polymath Module
A render of the prototype Polymath module with installed circuit board
project description
I designed this module as part of a project named “Polymath”, started by my roommate Zev Pogrebin and his friend Sam Cohen. Their idea was to build a modular synthesizer, to fill the gap in the synthesizer market between non-modular synths with too many options (making them too expensive) and modular synths with too many wires.
Their system uses a dock with 8 slots, each occupied by a module that slides in, connects to the synth, and locks in place. Each module will have an internally mounted circuit board connected to different knobs and sliders that protrude through the face, depending on the intended use of that specific module.
My job as mechanical design lead was to design this modular docking system and build a prototype. I started by designing and 3d printing sliding rails, attempting to discover the perfect tolerance between the faces. I improved and miniaturized my design, and then began to integrate a locking mechanism. The final version uses a spring loaded latch on the dock that lodges itself inside the module, locking it in place. I also designed two potential prototype designs, one manufactured using sheet metal, and one manufactured using laser cut wood. We decided to only build the laser cut wood design due to cost concerns.
An assembly animation of the prototype Polymath module
My first sliding rail design
V2 of the sliding rail design
V3 of the rail design, with included spring locking latch
3D printed Polymath module mounted on V3 of the rail design
The finished laser cut prototype of the Polymath module
Laser cut prototype fits on V3 of the rail design
The spring loaded latch in the back ensures that the module is locked in place
A concept render of a sheet metal Polymath module prototype
Side view of sheet metal prototype
An assembly animation for the sheet metal prototype