FINAL

REPORT
FOR A DIY MECHANICAL
CLOCK

PRESENTED TO: MOODY FARAG

PREPARED BY: GROUP PINK
RIDA FATHIMA
MOHAMMAD IMWAFI
RAJIB ALAM
AFNAN LAIBA

DATE: DECEMBER 06, 2024

Table of Contents
1. Introduction ..................................................................................................................... 4
2. Background ..................................................................................................................... 4
2.1 Problem Background....................................................................................................... 4
2.2 Research Findings .......................................................................................................... 4
3. Project Description ........................................................................................................... 5
3.1 Updated Plan of Work ..................................................................................................... 5
3.1.1. Need Statement ....................................................................................................... 5
3.1.2. Concept Combination and Sketching for Assemblies and Parts...................................... 5
3.1.3. Final Design Selection ............................................................................................. 5
3.1.4. Made a Project Proposal Presentation ......................................................................... 6
3.1.5. Created Freehand Sketches of the Clock Design .......................................................... 6
3.1.6. Bill of Materials (BOM) ........................................................................................... 6
3.1.7. Completed AutoCAD Drawings for the Finalised Design ............................................. 6
3.1.8. Prototyped with Cardboard Cutouts ........................................................................... 6
3.1.9. Construct main assembly .......................................................................................... 7
3.1.10. Test Debug ........................................................................................................... 7
3.1.11. Construct end product ............................................................................................ 7
3.1.12. Final Display and Upcoming Work .......................................................................... 7
3.2 Updated Project Schedule ................................................................................................ 8
4. Summary of Design Alternatives ........................................................................................ 8
4.1 Concepts ....................................................................................................................... 8
5. Design Selection Process ................................................................................................. 11
5.1 Selection Matrix ........................................................................................................... 11
5.2 Winning Concept.......................................................................................................... 12
6. Final Design .................................................................................................................. 12
7. Budget .......................................................................................................................... 15
8. Conclusion .................................................................................................................... 15
9. Authorization ................................................................................................................. 16
10. References ................................................................................................................. 16
11. Appendices ................................................................................................................ 16

2
Table of Figures
Figure 1: Cardboard cutouts made with our Trotec Speedy 400 laser-cutter ........................ 6
Figure 2: Revised Gantt Chart............................................................................................... 8
Figure 3: Concept C .............................................................................................................. 9
Figure 4: Concept E ............................................................................................................ 10
Figure 5. Final Design of the Clock ..................................................................................... 13
Figure 6: Picture of the Clock .............................................................................................. 14
Figure 7: Bill of Materials (BOM) ......................................................................................... 15

Table of Tables
Table 1: Concept Combination Chart ................................................................................... 9
Table 2: Selection Matrix..................................................................................................... 11
Table 3: Weighted Concept Scores ..................................................................................... 12

3
 1. Introduction
Our goal is to spark curiosity in the scientific, technological, and historical aspects of
timekeeping and clockmaking by designing a Do-It-Yourself kit of a Mechanical Clock that
will appeal to hobbyists, educators, and students.
Our DIY kit of a mechanical clock is powered mechanically without the usage of
electricity or batteries. Our research tells us that there is a niche market for mechanical clocks
that can be constructed from parts.
The invention of an accurate mechanical clock – operated with the aid of a pendulum and
an escapement – was a giant leap for humanity toward scientific and technological
progress. A DIY mechanical clock will illuminate the simplicity and brilliance of the design
principles that make it tick.
Furthermore, the hobby industry is booming both globally and, in the US, and
Canada. The DIY and Maker industry is thriving. The hobby industry is worth about $50
billion dollars, and we would like to be a part of it.

2. Background
2.1 Problem Background
The problem starts with the acknowledgment that modern technology has replaced
traditional mechanical clocks with digital and battery-powered ones. While these new clocks
are convenient, this has led to a loss of interest in and understanding of the amazing
engineering behind mechanical clocks. Most people, especially of younger generations, do
not have the opportunity to see or learn how these wonderful clocks work and why they were
so important historically.
This has created a gap in education. Students often learn about science and
engineering in ways that don’t feel practical or exciting. Mechanical clocks could be a fun
and hands-on way to teach important engineering ideas, like how pendulums and gears work
together. However, they are rarely used for teaching, meaning students miss out on a chance
to connect with both science and history.
At the same time, the DIY (Do-It-Yourself) and hobby markets are growing fast,
worth about $50 billion worldwide. But most of the projects in this market focus on digital
gadgets or crafts, with very few options for building something as unique as a mechanical
clock. This leaves hobbyists, educators, and students without an easy way to explore and
create something that combines history, creativity, and mechanical engineering.
This problem matters because it’s not just about making a cool clock; it’s about
reconnecting people with an important part of history, offering students a fun way to learn,
and giving hobbyists something new and exciting to build. Solving this problem could make
learning and creating both enjoyable and meaningful.

2.2 Research findings

• Primary Research

4
 To better understand the problem, we communicated with hobbyists, teachers, and
students through surveys and interviews. Teachers mentioned a big need for hands-on tools to
teach subjects like engineering and physics. They liked the idea of using mechanical clock
kits in classrooms. Hobbyists were excited about projects that mix creativity with mechanical
design, especially ones that don’t require batteries or electricity.
The surveys showed that many students and hobbyists want easy-to-use DIY kits.
People liked the idea of learning basic mechanics through a fun and engaging project. They
also said it’s important for the kit to have clear instructions and a simple design so that it is
easy for everyone to use.
• Secondary Research (Literature Review)
We looked at existing designs and market trends on sites like GrabCAD.com. We
found that there aren’t many DIY kits for building mechanical clocks, which shows that
there’s a gap in the market. Studies also showed that mechanical clocks are great for teaching
basic physical concepts, such as the science of pendulums and gear systems, which are
important concepts in engineering and physics.
Market research also showed that the DIY and hobby industries are growing quickly,
now worth around $50 billion. Many people are looking for creative projects that combine
learning and craftsmanship. However, most kits available focus on electronics or modern
designs, and there are very few that focus on building mechanical systems like clocks.
This research shows that there’s a clear need for a DIY mechanical clock kit to fill
this gap in education and the hobby market.

3. Project Description
3.1 Updated Plan of Work
Below is a detailed breakdown of the tasks we have completed so far:

3.1.1. Need Statement

Customer needs were gathered through peer surveys, identifying six key priorities:
affordability, portability, accuracy, ease of construction, educational value, and aesthetics.

3.1.2. Concept Combination and Sketching for Assemblies and Parts

Five design concepts were developed, combining ideas into tables and sketches
(Appendix B). These designs emphasized aesthetics and layout, while mechanical details
were deferred.

3.1.3. Final Design Selection

Using a rubric, we evaluated two concepts based on feasibility, functionality,
manufacturability, affordability, and user constraints like ease of assembly, readability, and
noise levels. Concept E, featuring a pendulum, Graham escapement, and weight-driven
power, was selected for its simplicity and effectiveness (Appendix B: Table 2).

5
3.1.4. Made a Project Proposal Presentation
During this presentation, we outlined the goals, methods, and expected outcomes for
our DIY Mechanical Clock project. The feedback received led to the refinement of our design
approach and solidified the project timeline. This step marked the formal start of the project,
allowing us to move forward with detailed design and development.

3.1.5. Created Freehand Sketches of the Clock Design

Freehand sketches were created in the early stages to visualize and explore different
design configurations. These sketches facilitated team communication and served as a
blueprint for developing detailed CAD models.

3.1.6. Bill of Materials (BOM)

We prepared a list of required materials including plywood, bearings, screws, shafts,
and other components required to build the DIY mechanical clock. By preparing the BOM
early, we ensured that all necessary materials were identified, priced, and ordered within
budget constraints.

3.1.7. Completed AutoCAD Drawings for the Finalised Design

We created precise 2D AutoCAD drawings for the finalized design, detailing part
dimensions. The completed drawings were submitted to ensure accuracy before proceeding
with CNC laser cutting.

3.1.8. Prototyped with Cardboard Cutouts

As seen in Figure 3, we obtained cardboard cutouts of our parts to create a rough
prototype of our clock before making the final cutouts out of plywood. This allowed us to
identify design flaws and make changes accordingly. For instance, we realized that our
escapement wheel was much too small, the dimensions of the recesses for our ball bearings
were too large, and parts such as columns and anchor pallets needed to be lengthened and
thickened to make them more robust. This step was indeed very useful in the design process.

Figure 1: Cardboard cutouts made

with our Trotec Speedy 400 laser-cutter
6
3.1.9. Construct main assembly
After testing the design using cardboard cutouts, we moved forward with creating the
final parts using Baltic Birch plywood. For this, we used the Trotec Speedy 400 laser cutter to
craft precise components, including gears and structural parts, based on our AutoCAD
designs. The plywood cutouts replaced the earlier cardboard prototypes and became the
backbone of the clock's main structure. We made sure every piece fit perfectly to avoid issues
later during assembly.

3.1.10. Test Debug

With the main assembly complete, we moved on to testing and debugging. This was
one of the most important phases, where we worked out any remaining issues in the design.
For example, we discovered that the escapement mechanism needed adjustments.
Specifically, with the dimensions of the escapement wheel, which then we fine-tuned to
ensure smoother energy transfer and improve reliability. Through repeated testing, we also
made small tweaks to the gear train and pendulum to get everything to work together.

3.1.11. Construct end product

Once the testing phase was complete, we focused on building the final product. This
involved assembling all the components into a fully functional clock. To give it a polished
and professional look, we sanded the plywood and applied paint, which not only enhanced
the appearance but also acted as a protective deal to improve durability.
We also prepared for the upcoming showcase by creating advertising materials. Our
video documents our entire process from the initial cardboard prototypes to the final product,
showing the technical and educational aspects of the project. Additionally, we designed
brochures to provide a detailed overview of the clock’s features, how it's assembled, and the
educational value it offers to make the presentation more engaging.

3.1.12. Final Display and Upcoming work

The final step is presenting our completed clock to the public. We’ll demonstrate how
it works, explain the design process, and highlight its educational value. Along with the
clock, we'll showcase an advertising video and hand out the brochures we prepared to share
our journey with the audience. This display will showcase the dedication and creativity that
went into bringing this project to life.

7
3.2 Updated Project Schedule

Figure 2: Revised Gantt Chart

Our Gantt chart captures the progress made in the project and the adjustments to our
timeline. The first phase, from week 1 to week 7 focused on cardboard prototyping to refine
the design. By week 8, materials were procured, and the fabrication of parts was completed
by week 10
From week 11 to 14 the team assembled the clock’s components, conducted tests, and
debugged any issues to ensure smooth functionality. In week 14, the final assembly began,
including sanding and painting, as well as preparing advertising materials such as a video and
brochures.
The project will conclude in week 16 with a public showcase, demonstrating the
clock, supported by the advertising materials.

4. Summary of Design Alternatives

4.1 Concepts
Essentially, a mechanical clock is composed of an oscillator, an escapement
mechanism, and a power source. An oscillator can either be a pendulum or a coiled spring,
also known as a balance spring. We have chosen a pendulum for our clock.
There are many types of escapements, but the most accurate pendulum clocks contain
a Graham escapement, which also happens to be the type of escapement that we will be
implementing in our clock.
A mechanical clock can be powered by a weight or a coiled spring, also known as a
mainspring. We chose a weight to power our clock.
We designed five concepts as potential candidates for our mechanical clock. Our
concept combination chart consisted of the following.

8
 Oscillator Escapement Power-source

Pendulum Recoil Anchor Weight (Gravity)

Balance-Spring (with Balance-Wheel) Deadbeat Mainspring (Elastic)

Lever

Verge
Table 1: Concept Combination Chart

Figure 3: Concept C

As an example, the preceding sketch shows our concept, Concept C, of a mechanical

clock with a balance-spring, a Swiss-lever escapement, and a weight.
The following sketch shows our concept, Concept E, of a mechanical clock with a
pendulum, a Graham escapement (also known as a deadbeat escapement), and a weight.

9
 Figure 4: Concept E

Concept A was designed with a recoil anchor, a pendulum, and a weight, Concept B
was designed with a recoil anchor, a pendulum, and a mainspring, and Concept D was
designed with a balance-spring, a lever, and a mainspring.

10
 5. Design Selection Process

5.1 Selection Matrix

Selection Criteria Concept

A B C D E

Cost of Materials + 0 0 - +

Total Mass 0 + 0 + 0

Accuracy of Oscillator - - 0 0 0

Complexity of Internal Mechanisms + 0 0 - +

Ease of Manufacture + 0 0 - +

Noise 0 0 0 0 +

Tools Required for DIY + - 0 - +

Portability - 0 0 + -

Sum +’s 4 1 0 2 5

Sum 0’s 2 5 8 2 2

Sum –’s 2 2 0 4 1

Net Score 2 -1 0 -2 4

Rank 2 4 3 4 1

Continue? No No Yes No Yes

Table 2: Selection Matrix

Our selection matrix in Table 2 indicated that Concept C and Concept E are our
highest-ranked design concepts.

11
 5.2 Winning Concept
After scrutinizing and scoring our five concepts, we arrived at our weighted concept
scores. Portability, cost of materials, ease of construction, total mass, accuracy, and degree of
complexity were all weighted heavily in our analysis.
Our runner-up is Concept C, the aforementioned mechanical clock equipped with a
hairspring, a Swiss-lever escapement, and a weight. Though we would very much like to
build and sell this concept, a balance-spring and a Swiss-lever escapement are both much
more complex than a pendulum and a Graham escapement. This would significantly increase
the cost of production, and complicate its manufacturing process.

Concept C Concept E

Selection Criteria Weight Rating Weighted Rating Weighted

(%) Score Score
Cost of Materials 20 3 .6 4 .8
Total Mass 10 3 .3 3 .3
Accuracy of Oscillator 15 3 .45 3 .45
Complexity of Internal 15 3 .45 4 .6
Mechanisms
Ease of Construction 20 3 .6 4 .8
Noise 5 3 .15 3 .15
Tools Required for DIY 5 3 .15 4 .2
Portability 10 3 .3 5 .5
Total 3.0 3.8
Score
Rank 2 1

Continue No Yes

Table 3: Weighted Concept Scores

As our weighted concept scores in Table 2 indicate, Concept E — our concept with a
pendulum, a Graham escapement, and weight — was the clear winner among our five
concepts. The Graham escapement is a simple yet highly accurate escapement that is used in
nearly all high-quality pendulum clocks. Concept E satisfies much of the requirements of our
needs statement, and so it offers our customers a product that is sure to delight while
minimizing the cost of production.

6. Final Design
Our end product satisfies much of the criteria that we set out to achieve in our needs
statement. To reiterate, our priorities have been to construct a clock that is aesthetically
pleasing, simple and easy to construct, affordable, light and portable, and in which the
components are easily observed.
12
 After many revisions of Concept E, we constructed the following sketch for our end
product.

Figure 5. Final Design of the Clock

13
 Without further ado, we are excited to present the final design of our mechanical
clock.

Figure 6: Picture of the Clock

14
 The entire clock has been sustainably constructed. Materials are either recyclable,
compostable, or reusable. Much of it is constructed from top-tier Baltic Birch plywood,
which is ideal for laser-cutting. Two of the shafts are made of aluminum, while the webbing
for winding the clock is made of recycled nylon.
The charring of the wood during the laser-cutting process contrasts beautifully with
the birch ply, while the brass accents remind us of the historical age of mechanical clocks.
Plywood is also a very light material, which adds to the lightness and portability of
our clock. To further reduce costs and the weight of the clock, and to speed up the laser-
cutting process, we chose to work with 3mm plywood. As a result, the entire clock weighs
less than a kilogram.
3mm plywood is also very quick and easy to cut with a laser-cutter. This is relevant
as we will be laser-cutting the gears, the escapement mechanism and other parts for future
orders. In addition to being a sustainable resource, plywood is also relatively cheap. This
adds to the affordability of our clock.
Unlike other materials, such as acrylic, which can be brittle, plywood is also very pliable (pun
not intended), which is important since our clock will not be prone to chipping or cracking
while being shipped to our customers.
Last, but not least, our clock’s open design naturally invites our customers to
scrutinize the mechanisms of a working mechanical clock. Customers will appreciate the
smooth tick-tocking of the Graham escapement while observing the smooth rotation of the
interlocking gears.

7. Budget

Figure 7: Bill of Materials (BOM)

The total budget for the mechanical clock project was $84.14, covering all required
materials. Key expenditures included Baltic Birch plywood, ball bearings, screws, and
dowels, sourced from vendors like Amazon, Home Depot, and Michaels. This cost-effective
selection ensured high-quality components while staying within budget constraints.

8. Conclusion
Our DIY Mechanical Clock project has successfully combined the principles of
engineering, education, and creativity to create a hands-on tool that inspires curiosity in
timekeeping and mechanical design. By addressing the gaps in STEM education and the

15
hobbyist market, our affordable and easy-to-assemble mechanical clock kit demonstrates the
intricate workings of pendulums, escapements, and gears in a way that is both accessible and
engaging.
Throughout this project, we applied a structured approach, progressing through the
identification of customer needs, conceptual designs, detailed sketches, and prototype
development. Despite challenges, such as material delays and design revisions, our team
remained adaptive and solution-focused, leading to a refined product that balances
functionality, aesthetics, and affordability.
As we move into the final stages of assembly and testing, we are confident that the
finished product will meet our objectives and provide value to educators, students, and
hobbyists. This project has been a rewarding journey, showcasing the importance of
teamwork, innovation, and dedication in addressing real-world engineering challenges.

9. Authorization
This final report is submitted on behalf of Group Pink, comprising Mohammad
Imwafi, Rida Fathima, Rajib Alam, and Afnan Laiba. We confirm that all findings, designs,
and deliverables presented in this report are the result of our collaborative effort. We seek
approval and feedback from our instructors, Moody Farag and Ali Taha, to ensure the
continued refinement and successful completion of this project.
We thank you for your guidance and support throughout the development of this
project and look forward to showcasing the final product. Should there be any additional
information or clarification required, we would be happy to provide it.

10. References
Progress Report: Appendix A
Proposal Report: Appendix B

11. Appendices
APPENDIX A: PROGRESS REPORT for a DIY MECHANICAL CLOCK
APPENDIX B: PROJECT PROPOSAL for a DIY MECHANICAL CLOCK

16
 PROGRESS
REPORT
FOR A DIY MECHANICAL
CLOCK

PRESENTED TO: MOODY FARAG

PREPARED BY: GROUP PINK
RIDA FATHIMA
MOHAMMAD IMWAFI
RAJIB ALAM
AFNAN LAIBA

DATE: NOVEMBER 18, 2024

1
TABLE OF CONTENTS
1. INTRODUCTION ............................................................................................................ 3
2. PROGRESS SUMMARY ................................................................................................. 4
2.1 PLAN OF WORK .......................................................................................................... 4
2.1.1. Need Statement ....................................................................................................... 4
2.1.2. Concept Combination and Sketching for Assemblies and Parts...................................... 4
2.1.3. Final Design Selection ............................................................................................. 4
2.1.4. Made a Project Proposal Presentation ......................................................................... 4
2.1.5. Created Freehand Sketches of the Clock Design .......................................................... 4
2.1.6. Bill of Materials (BOM) ........................................................................................... 4
2.1.7. Completed AutoCAD Drawings for the Finalised Design ............................................. 5
2.1.8. Prototyped with Cardboard Cutouts ........................................................................... 6
2.2.1 ORIGINAL PROJECT SCHEDULE .............................................................................. 7
2.2.2 UPDATED PROJECT SCHEDULE .............................................................................. 7
2.3 TASK BREAKDOWN .................................................................................................... 8
2.3.1 TASK COMPLETED ............................................................................................... 8
2.3.2 TASK REMAINING ................................................................................................ 9
2.3.3 MAJOR MILESTONES ............................................................................................ 9
ACHIEVED MILESTONES.............................................................................................. 9
UPCOMING MILESTONES ........................................................................................... 10
3. PROBLEMS/CHANGES TO PROJECT ........................................................................... 10
4. CONCLUSION .............................................................................................................. 10
5. REFERENCES .............................................................................................................. 11
6. APPENDICES ............................................................................................................... 11

TABLE OF FIGURES
Figure 1: Bill Of Materials ...................................................................................................................... 5
Figure 2: AutoCAD Overall Clock Design and Side-view ..................................................................... 5
Figure 3: Cardboard cutouts made with our Trotec Speedy 400 laser-cutter......................................... 6
Figure 4: Original Gantt Chart ................................................................................................................ 7
Figure 5: Revised Gantt Chart ................................................................................................................ 7
Figure 6: Work Breakdown Structure ..................................................................................................... 8
Figure 7: Milestone Breakdown.............................................................................................................. 9

2
 1. INTRODUCTION
Our goal is to inspire interest in the scientific, technological, and historical aspects of
timekeeping and clock-making by designing a Do-It-Yourself Mechanical clock kit. By focusing on
hobbyists, educators, and students, this kit emphasises the educational significance of traditional
principles in mechanical timekeeping. Current educational tools lack a hands-on, mechanical-based
approach to demonstrate these principles without using electricity or batteries. Our project aims to fill
this gap by designing a DIY mechanical clock kit that is affordable, easy to assemble, portable,
accurate, and aesthetically pleasing, allowing users to appreciate the inner workings and historical
significance of mechanical timekeeping.

To achieve the project's success, we have defined several objectives, including reviewing
literature on the history and development of the mechanical clock designs, and comprehensive
engineering drawings. An extensive review of historical literature was taken to explore the evolution
of mechanical clock designs, focusing on advancements in pendulums, escapement mechanisms, and
related components that transformed timekeeping. This historical perspective lays a solid foundation
for understanding the traditional techniques that continue to influence modern horology. We
conducted comprehensive engineering and design work to create detailed drawings and assembly
details.

Assembling the clock by hand allows users to engage directly with the function of pendulums,
and the escapement mechanism, which releases energy and ensures a consistent time cycle. Through
this interactive approach, users gain a deeper appreciation for the mechanics between the gears, the
escapement, the pendulum and other clock components, showcasing the elegance of traditional
mechanical design.

To meet the diverse needs of our target audience, the kit is designed with affordability,
portability, accuracy, and aesthetic appeal in mind. We are committed to creating a cost-effective
product that is easily accessible to schools, hobbyists, and enthusiasts. The kit’s compact design
ensures it is suitable for workshops and classroom demonstrations, making it an effective educational
tool. Precision engineering in deciding the gear ratio is used to maintain accurate timekeeping, while
the clock’s aesthetic appeal showcases the beauty and craftsmanship inherent in mechanical
clockwork, creating a visually captivating product.

The invention of the mechanical clock, using a pendulum and an escapement, was a milestone
in science and technology. A DIY clock kit reveals how these key parts work together to keep
accurate time, offering a hands-on way to appreciate its mechanics, history, and engineering. Our
progress thus far includes detailed historical research and engineering planning, laying the
groundwork for a product that captivates and educates users, fostering a deep appreciation for the art
and science of clock-making.

3
 2. PROGRESS SUMMARY

2.1 PLAN OF WORK

Below is a detailed breakdown of the tasks we have completed so far:

2.1.1. Need Statement

We have gathered customer needs by conducting surveys among peers and identified six
primary customer needs, including affordability, portability, accuracy, ease of construction,
educational focus, and aesthetics.

2.1.2. Concept Combination and Sketching for Assemblies and Parts

We designed five concepts as potential candidates for our mechanical clock. We first listed all
the desirable combinations of the concepts in the form of a table. Furthermore, we sketched each
combined concept to have a clearer view of the design. There is a clear view of these concepts
available in Appendix A. The concept design focuses more on the aesthetics and the layouts of the
clock components and not on the details of the mechanical systems behind it. The mechanical gearing
systems of the clock were not explored in detail during this week.

2.1.3. Final Design Selection

We finalised the main and subassembly design sketches by means of a rubric that evaluated
the pros and cons of our two concepts. The rubric for design selection was designed to assess
compliance with the design brief and list of specifications. This included factors such as feasibility,
functionality, manufacturability, affordability, materials constraints, and user constraints such as ease
of assembly, reading time, and noise level. Our winning design was Concept E, which features a
pendulum, a Graham escapement, and a weight-based power source due to its simplicity and
effectiveness. Refer to Appendix A: Table 2 for more detailed information on this.

2.1.4. Made a Project Proposal Presentation

During this presentation, we outlined the goals, methods, and expected outcomes for our DIY
Mechanical Clock project. The feedback received led to the refinement of our design approach and
solidified the project timeline. This step marked the formal start of the project, allowing us to move
forward with detailed design and development.

2.1.5. Created Freehand Sketches of the Clock Design

Freehand sketches were created in the early stages to visualise and explore different design
configurations. These sketches facilitated team communication and served as a blueprint for
developing detailed CAD models.

2.1.6. Bill of Materials (BOM)

We prepared a list of required materials including plywood, bearings, screws, shafts, and
other components required to build the DIY mechanical clock. By preparing the BOM early, we
ensured that all necessary materials were identified, priced, and ordered within budget constraints.

4
 Figure 1: Bill Of Materials

2.1.7. Completed AutoCAD Drawings for the Finalised Design

We created precise 2D AutoCAD drawings for the finalised design, detailing part dimensions.
The completed drawings were submitted to ensure accuracy before proceeding with CNC laser
cutting.

Figure 2: AutoCAD Overall Clock Design and Side-view

5
2.1.8. Prototyped with Cardboard Cutouts
As seen in Figure 3, we obtained cardboard cutouts of our parts to create a rough prototype of
our clock before making the final cutouts out of plywood. This allowed us to identify design flaws
and make changes accordingly. For instance, we realized that our escapement wheel was much too
small, the dimensions of the recesses for our ball-bearings were too large, and parts such as columns
and anchor-pallets need to be lengthened and thickened to make them more robust. This step was
indeed very useful in the design process.

Figure 3: Cardboard cutouts made with our Trotec Speedy 400 laser-cutter

6
2.2.1 ORIGINAL PROJECT SCHEDULE

Figure 4: Original Gantt Chart

This chart represents the initial project timeline and planned tasks, outlining the sequence and
duration of each activity.

2.2.2 UPDATED PROJECT SCHEDULE

Figure 5: Revised Gantt Chart

This updated chart reflects adjustments made during project execution including completed tasks and
any scheduled shifts. Notably, it incorporates delays in CNC part cutouts and highlights the current
progress.

The revised Gantt chart highlights the adjustments made since the initial project schedule
outlined in the progress report. This updated version includes a light blue shaded box indicating tasks
that have already been completed. Currently, we are entering Week 11. Construction of the main body
and parts will commence upon the arrival of our plywood material at the beginning of Week 11.

There was a slight delay in the CNC parts cutout process, which began in Week 8 and
extended through Week 10. Despite this delay, the trials and testing phases of the components have
been successfully completed. This minor adjustment has not caused significant disruption to the
overall project timeline initially proposed. We are now prepared to proceed with the final stages,
including parts assembly and sub-assembly, ensuring the project remains on track.

7
2.3 TASK BREAKDOWN

Figure 6: Work Breakdown Structure

The Work Breakdown Structure (WBS) shown above organises the DIY mechanical clock
project into four main phases: identifying customer needs, design and planning, component
fabrication and assembly, and testing/finishing. Each phase is broken down into specific tasks to
streamline the process from concept development to the final presentation of the completed product.
The production section focuses on the clock’s mechanical systems like power transmission and
control mechanisms, while the documentation section details necessary engineering processes and
required documents (e.g., design specifications, sketches, and project timing). The Work Breakdown
Structure served as a checklist and guided task allocation to ensure project success.

2.3.1 TASK COMPLETED

We have successfully completed over half of the essential work for this project. So far, we
have conducted comprehensive need assessments, developed design concepts, finalised detailed
sketches, designed gear-train, created a bill of materials, and prototyped with cardboard cutouts of our
parts. Additionally, we acquired proficiency in software necessary for generating project components
and translated our designs into AutoCAD for precise laser cutting of the clock parts. According to our
Work breakdown Structure (Figure 5), we are currently in the Component Fabrication and Assembly
phase, where the final CNC parts are being printed and raw materials like plywood, acrylic, and MDF
are awaited.

8
2.3.2 TASK REMAINING
The remaining tasks involve the arrival of raw materials, including plywood, acrylic, and
MDF, followed by the final CNC parts printing. We will then proceed with constructing the main
assembly and sub-assemblies, integrating all components. This will be followed by testing and
debugging to ensure functionality, as well as preparing for advertising and the final display of the
completed product.

2.3.3 MAJOR MILESTONES

Figure 7: Milestone Breakdown

ACHIEVED MILESTONES
MILESTONE 1: Concept Selection
A big milestone in the project was finalising the design concept. A detailed evaluation process
was conducted to assess the feasibility, functionality, and overall effectiveness of each concept. This
rigorous selection process led to the identification of the most suitable concept, marking a critical
turning point in the project. This decision helped us create the full design and plan for building the
clock.

MILESTONE 2: Approval on the Selected Design

A key milestone was the success of our proposal presentation, where we presented our
research, findings, specifications, material selection, and gear-train mechanism. After thorough
evaluation, we received approval from our professor to proceed, confirming the project is ready to
progress to the prototype phase.

9
UPCOMING MILESTONES
MILESTONE 3: Component Fabrication and Assembly
Assemble all clock components, including the housing, escapement, gear-train, and the
panels, to create a functional physical prototype that aligns with the approved design.

MILESTONE 4: Final Showcase and Presentation

Prepare for the final showcase and presentation by refining the clock’s features, testing for
reliability and rehearsing the project demonstration.

3. PROBLEMS/CHANGES TO PROJECT
The process thus far of creating the clock has been relatively smooth, with some challenges
that provided valuable learning experiences. One significant issue arose during the design of the gear
train. Our initial plan was to keep the shape of the clock and its internal mechanisms horizontal.
However, after consulting with our professor for feedback, we were advised to adopt a vertical design.
This change reduced the overall length of the clock and minimised wasted space, requiring us to also
modify the clock's outer housing.

Another challenge was the delayed arrival of raw materials, which were delivered a week
later than expected. It was difficult to find a vendor for the 3mm plywood that we will be using to
construct our clock. Though there are several vendors in the Greater Toronto Area who sell plywood,
most do not carry high-quality Baltic Birch plywood that is required for the purpose of laser-cutting
precision parts for our clock. We were eventually able to source the requisite plywood from Ply
Supply.

We also encountered design accuracy issues while creating the drawing model in AutoCAD.
This required redrawing and re-measuring parts, such as the escapement wheel and anchor. Despite
the challenges we faced, our team demonstrated adaptability, effective problem-solving, and a
commitment to excellence throughout the project. Each change we implemented contributed to a more
efficient and refined design, ultimately improving the overall functionality and aesthetics of the clock.

4. CONCLUSION
To conclude, our DIY Mechanical Clock project aims to inspire interest in the scientific,
technological, and historical aspects of timekeeping through an educational tool tailored for hobbyists,
educators, and students. By designing an affordable, accurate, portable, and aesthetically pleasing
mechanical clock kit, we strive to fill a gap in mechanical timekeeping education while celebrating
traditional principles of clock-making.

Our progress reflects a structured approach, with completed phases in design and planning,
including customer needs assessment, concept selection, and design approval. Despite challenges such
as gear-train adjustments, delayed materials, and AutoCAD accuracy issues, we adapted through
collaboration and problem-solving, resulting in a stronger final design. As we move into the final
assembly and testing phases, we aim to deliver a functional, accurate, and visually appealing product
that meets our objectives.

We welcome your feedback and kindly seek your continued support and approval as we
progress towards completing and showcasing the final product. Your insights will be invaluable in
refining our work and ensuring its impact as an engaging educational resource.

10
 5. REFERENCES
Proposal Report: Appendix A

6. APPENDICES
APPENDIX A: PROJECT PROPOSAL for a DIY MECHANICAL CLOCK

11
 PROJECT PROPOSAL
for a
DIY MECHANICAL CLOCK

Prepared for: Moody Farag

Prepared by: Group Pink
Rida Fathima
Mohammad Imwafi
Rajib Alam
Date: October 18, 2024

1
Table of Contents
Summary Of Problem and Project Description 3
Team Members 3
Research Findings of Customer Needs 4
Concepts 5
Selection Matrix 9
Winning Concept 9
Plan, Schedule and Work Structure 11
Deliverable (Final Design) 13
Budget (Bill Of Materials) 17
Resource Requirements 17

2
SUMMARY OF PROBLEM AND
PROJECT DESCRIPTION
Our goal is to spark curiosity in the scientific, technological and
historical aspects of timekeeping and clockmaking by designing a
Do-It-Yourself kit of a Mechanical Clock that will appeal to hobbyists,
educators and students.
Our DIY kit of a mechanical clock is powered mechanically without
the usage of electricity or batteries. Our research tells us that there is a niche
market for mechanical clocks that can be constructed from parts.
The invention of an accurate mechanical clock – operated with the aid
of a pendulum and an escapement – was a giant leap for humanity toward
scientific and technological progress. A DIY mechanical clock will illuminate
the simplicity and brilliance of the design principles which make it tick.
Furthermore, the hobby industry is booming both globally and in the
US and Canada. The DIY and Maker industry is thriving. The hobby
industry is worth about $50 billion dollars, and we would like to be a part of
it.

TEAM MEMBERS
We are a team of three Engineering students at Humber Polytechnic. Our group
comprises Rida Fathima, Mohammad Imwafi and Rajib Alam. We will share all
responsibilities equally in order to bring our DIY mechanical clock to fruition.

3
RESEARCH FINDINGS OF
CUSTOMER NEEDS
In order to determine the needs of potential customers, we cast a wide
net and surveyed our peers, acquaintances, friends, family members and
relatives.
We were able to boil down our customers’ needs to six primary factors.
Our research indicates that we must design a clock which is (ranked by
importance):

● AFFORDABLE
○ The bill of materials for our clock is $40. We intend to sell our
clock for $75.
● LIGHT/PORTABLE
○ This is a priority for both us and our customers in order to
maximize ease of handling, and minimize shipping costs.
● ACCURATE – INFREQUENT ADJUSTMENT
○ Customers desire a clock which does not require frequent
adjustment. We intend to make our clocks with an error-margin
of less than a minute a day, which is certainly attainable since
pendulum clocks of the twentieth century had an error-margin
of less than a minute per week.
● EASY TO CONSTRUCT – NOT EXCESSIVELY
COMPLEX
○ We think that the level of complexity of our DIY clocks will
appeal to most adolescents and adults.

4
 ○ A mechanical clock constructed with a pendulum and an
escapement is a remarkably simple apparatus despite its enormous
utility and accuracy.
● COMPONENTS ARE EASILY OBSERVED AND
STUDIED
○ Hobbyists and enthusiasts wish to watch and appreciate the
internal mechanisms of a clock, which is a major selling point of
our DIY clock. This is why we will be constructing our clock
with transparent acrylic.
● AESTHETICALLY PLEASING
○ A majority of our customers will want to hang their clocks on a
wall where they and others can observe and admire its intricacies.
Thus, aesthetics is a major priority as well.

CONCEPTS
Essentially, a mechanical clock is composed of an oscillator,an
escapement mechanism, and a power-source.

An oscillator can either be a pendulum or a coiled spring, also known

as a balance-spring. We have chosen a pendulum for our clock.
There are many types of escapements, but most accurate pendulum
clocks contain a Graham escapement, which also happens to be the type of
escapement that we will be implementing in our clock.
A mechanical clock can be powered by a weight or a coiled spring, also
known as a mainspring. We have chosen a weight to power our clock.

5
 We designed five concepts as potential candidates for our mechanical
clock.
Our concept combination chart consisted of the following.

Oscillator Escapement Power-source

Pendulum Recoil Anchor Weight (Gravity)

Balance-Spring (with Deadbeat Mainspring (Elastic)

Balance-Wheel)

Lever

Verge

As an example, Figure 1 shows our concept, Concept C, of a

mechanical clock with a balance-spring, a Swiss-lever escapement and a
weight.
And Figure 2 shows our concept, Concept E, of a mechanical clock
with a pendulum, a Graham escapement (also known as a deadbeat
escapement), and a weight.

6
Figure 1: Concept C

7
 Figure 2: Concept E

Concept A was designed with a recoil anchor, a pendulum and a

weight, Concept B was designed with a recoil anchor, a pendulum and a
mainspring, and Concept D was designed with a balance-spring, a lever and a
mainspring.

8
SELECTION MATRIX
Selection Criteria Concept
A B C D E
Cost of Materials + 0 0 - +
Total Mass 0 + 0 + 0
Accuracy of Oscillator - - 0 0 0
Complexity of Internal + 0 0 - +
Mechanisms
Ease of Manufacture + 0 0 - +
Noise 0 0 0 0 +
Tools Required for DIY + - 0 - +
Portability - 0 0 + -

Sum +’s 4 1 0 2 5
Sum 0’s 2 5 8 2 2
Sum –’s 2 2 0 4 1
Net Score 2 -1 0 -2 4
Rank 2 4 3 4 1
Continue? No No Yes No Yes
Table 1: Selection Matrix

Our selection matrix in Table1 indicated to us that Concept C and

Concept E are our highest ranked design concepts.

WINNING CONCEPT
After scrutinizing and scoring our five concepts, we arrived at our
weighted concept scores.
Portability, cost of materials, ease of construction, total mass, accuracy
and degree of complexity were all weighted heavily in our analysis.

9
 Our runner-up is Concept C, the aforementioned mechanical clock
equipped with a hairspring, a Swiss-lever escapement and a weight. Though
we would very much like to build and sell this concept, a balance-spring and
a Swiss-lever escapement are both much more complex than a pendulum and
a Graham escapement.

Concept C Concept E
Selection Weight (%) Rating Weighted Score Rating Weighted Score
Criteria
Cost of 20 3 .6 4 .8
Materials
Total Mass 10 3 .3 3 .3
Accuracy of 15 3 .45 3 .45
Oscillator
Complexity of 15 3 .45 4 .6
Internal
Mechanisms
Ease of 20 3 .6 4 .8
Construction
Noise 5 3 .15 3 .15
Tools Required 5 3 .15 4 .2
for DIY
Portability 10 3 .3 5 .5
Total Score 3.0 3.8
Rank 2 1
Continue No Yes
Table 2: Weighted Concept Scores

As our weighted concept scores in Table 2 indicate, Concept E — our

concept with a pendulum, a Graham escapement, and a weight — was the
clear winner among our five concepts. In fact, the Graham escapement is a

10
simple yet highly accurate escapement that is used in nearly all high-quality
pendulum clocks.

PLAN, SCHEDULE AND WORK

STRUCTURE
Schedule
Early Late
Activity ES EF LS LF
Activity Description Duration in Slack
Weeks
1 Construct Needs Statement 2 0 2 0 2 0
2 Determine Specs/Metrics 1 2 3 2 3 0
3 Design and Sketch Concepts 1 3 4 3 4 0

4 Select a Concept 1 4 5 4 5 0
5 Make Detailed Sketches 1 5 6 5 6 0
6 Finalize Design (Main Assembly, 1 6 7 6 7 0
Subassembly and Parts)
7 Create Bill of Materials (BOM) 1 7 8 7 8 0
8 Order Materials (Bearings, Bushings, Pins) 2 8 10 8 10 0
9 Gather Raw Materials (Acrylic, MDF) 1 5 6 7 8 2
10 CNC Parts 2 8 10 8 10 0
11 Construct Parts and Subassembly 1 10 11 10 11 0
12 Construct Main Assembly 1 11 12 11 12 0
13 Test and Debug 2 12 14 12 14 0
14 Construct End-Product 2 14 16 14 16 0
15 Final Display
Table 3: Schedule

11
 As seen here, we have mapped out a tight timeline for the development
of our DIY clock; there is only a slack-time of two weeks for gathering raw
materials such as acrylic and MDF.
We just completed the final design of our clock, which is stage 6 of our
product-development schedule. That leaves us with another seven weeks to
complete our project. We are currently drawing up our bill of materials, and
will be ordering materials, such as bearings, bushings and pins next week.
Our GANT chart further lays out our path ahead, for those who prefer
a visual representation of our schedule.

Weeks From Start

Activity 0 2 4 6 8 10 12 14

Construct Needs
Statement

Determine
Specs/Metrics

Design and Sketch

Concepts

Select a Concept

Make Detailed
Sketches

Finalize Design
(Main Assembly,
Subassembly and
Parts)

12
Create Bill of
Materials (BOM)

Order Materials
(Bearings,
Bushings, Pins)

Gather Raw
Materials (Acrylic,
MDF)

CNC Parts

Construct Parts
and Subassembly

Construct Main
Assembly

Test and Debug

Construct
End-Product

Display
End-Product
Table 4: GANT Chart

Slack

DELIVERABLE (FINAL DESIGN)

To reiterate, the final design of our clock consists of a pendulum, a Graham
escapement, and a weight to drive it. We are excited to present our design
sketches here!

13
Figure 3: Sketch of DIY Mechanical Clock

14
Figure 4: Escapement Wheel, Anchor and Pallet

15
Figure 5: Side-view of Escapement and Pendulum.

16
BUDGET (BILL OF MATERIALS)
We have yet to determine our bill of materials, though we expect it to be less
than $75.

RESOURCE REQUIREMENTS
We will be using the labs and equipment, such as CNC machines, laser
cutters, available at Humber Polytechnic. Furthermore, we will be mentored
by Mr. Ali Taha for this project.

17