During this whole design, I went through it like I think many students would. I eyeballed the majority of the measurements, then slowly started realizing how precise each measurement needed to be. Everything is mocked up to fit snug but not restricting, and it printed exactly like I needed it to.
The fun part, aside from designing and printing in what still seems like magic, was doing the electrical. I haven't done circuit work since my days in college as a physics student, so this was an absolute blast (and challenge... a big challenge. More on that later). Using a soldering kit, I was able to hook the battery to the switch to the resistor to the LED light. This is magic to me and I'm totally digging it.
Unfortunately, it didn't go as planned (no surprise there). It started out just fine, working like it's supposed to, so I took it inside, showed my wife, and we had a little lunch. During lunch, the battery started popping. I quickly unplugged it and realized that it was overheating. There was a cross-up somewhere in the circuit, but I couldn't see it. After lunch, the switch got unscrewed and my problem was revealed. As I was screwing in the switch, the positive and negative wires had tangled, causing a short. After re-taping them and screwing the switch in more carefully, it worked just fine.
After printing finished and I got the casing cleaned up, which took a little bit of time due to the smoothness required to fend off the harboring of bacteria in the NICU, I tested out the switch and was happy with the result. A pretty sweet addition to this was having my 4 year-old work with the soldering gun and actually help with some of the assembly. No need, I was there the whole time to make sure the only hands that would be damaged were my own.
Second, do all research thoroughly. I looked into how to create a circuit, then went to Radio Shack and had them hook me up. I took the advice of a guy at the store and just ran with it. Bad idea. Next time, I'll due better groundwork and not just trust the word of someone I don't know. Come to find out, the 9-Volt option is one of the worst ones I could've chosen.
Third, be willing to take a risk. Matt Vaudrey and I bring this up all the time in our trainings, but it's so true. I stuck my neck pretty far outside of what I'm capable of and just went for it. Sure, I had the support of others, but that's what this whole learning thing is all about anyways, isn't it? It was so much fun learning about topics and being refreshed on others. That's how people live into their later years, or so I hear, by continuing to give their brains exercise.
Happy Short Circuit Fishing