1. Make craftsmanship key – Many people think that “down and dirty” breadboards save time and money. The problem is that if something isn’t working the way you want, down and dirty breadboards don’t tell you what the problem is – is it the mechanism design or the craftsmanship? Taking time to figure that out wastes the time and money you thought you were saving with the breadboards. Meeting deadlines is important, but meeting deadlines with useable products is more important; you should work in a way that allows you to easily determine if craftsmanship is the culprit – and if it isn’t, you can more quickly change your focus to the design.
2. Eliminate friction – Friction is the enemy of any mechanism. If you advance your gear train by hand, lubricate gears and other friction points, add small points of bearing surface where contact is made, and keep your mechanism lightweight and smooth, friction and drag on the movements of your mechanism should be at the very minimum and everything should run smoothly and freely.
3. Minimize parts – Keep it simple and eliminate as many parts as possible. A low parts count not only reduces manufacturing costs, it also makes assembly easier.
4. Determine inputs and outputs – Even if you have one very specific input, there is probably more than one output possible, and you should be aware of all of them. Inversely, if you have a required output, analyze all of the various inputs that can result in that required output.
5. Use the proper materials – Different materials are necessary for different jobs. Evaluate each part before you get started to determine if ABS, polypropylene, acetal, nylon, polycarbonate, metal, or some other material is the best choice.
6. Understand the math – Take the time to figure out the math that governs your mechanism. If you have the math figured out before you get started, adjustments are easier to make and can be made more quickly.
7. Ask others for their input – As they say, two heads are better than one. Discuss your mechanism with a great team and you’ll be surprised at how many other changes and improvements you can find to make your mechanism better.