It was the goal of this thesis to use skill sets and manufacturing methods discussed or introduced but not practiced in the undergraduate curriculum for mechanical engineers to create a working prototype of a musical instrument effect pedal. Specifically these skills include post-failure metallurgical examinations and circuit board design, and the manufacturing methods include metal forming (not cutting) with a lathe and sand casting. A musical instrument effect was chosen because it is a simple device with relatively simple circuitry, yet it still poses issues of system integration and design problems on multiple fronts. A typical design process was followed. However, in choosing manufacturing processes typical factors were examined (cost, rate, quality, etc.) as well as the stipulation that the process chosen must have been practiced before in the curriculum, forcing the designer to encounter different challenges and learn the detailed workings of an unfamiliar process. Finally recommendations concerning assembly and process modifications for mass production were given in light of the experience gained from building the prototype.
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