The objective of this project was to design and fabricate a cost-effective safety barrier and engagement mechanism for a 1960s-era impact testing machine, prioritizing user protection, usability, budget, and portability. The design needed to:

1. Fully protect users from projectiles and the swing arm itself

2. Be ergonomic and intuitive to encourage proper use

3. Stay within a strict $100 budget

4. Be easily disassemblable and portable
   
   

The first priority—user protection—required extensive research into appropriate materials. Using the original machine manual, which specified the maximum energy output of the swing arm, I determined baseline requirements for projectile protection. Combining this with material testing data, I specified optimal thicknesses and configurations of polycarbonate and sheet metal to absorb potential impact while maintaining visibility and structural integrity.

Ergonomics and accessibility were addressed through the strategic placement of hinges and handles, ensuring operators could safely prime, reset, and interact with the machine without difficulty. Recognizing that poorly designed interfaces often lead to improper use or neglect, usability was treated as a key design parameter.

Cost-effectiveness was achieved by using wood for the primary structural components, providing a sturdy yet affordable framework. The final design balanced safety, functionality, portability, and budget, demonstrating a practical, research-driven engineering solution.