Freestyle Project #8: Outlet Protector 5/21/25

Designing an outlet protector in Fusion 360 began with a clear goal: keep little ones safe without sacrificing style. I wanted a cover that snaps securely into a standard North American duplex receptacle, stays flush with the wall plate, and can be removed easily by an adult. Framing these requirements guided every step of the CAD process, ensuring the final model would be both functional and user-friendly.

On the Front plane, I sketched a circle for the base, setting its outer diameter to 30 mm and the inner lip diameter to 26 mm for a firm press fit against the socket face. From that same sketch, I extruded the base 5 mm deep, then sketched and extruded three rectangular prongs 4 mm wide, 1 mm thick, and 15 mm tall to align perfectly with outlet slots. Every dimension was driven by named parameters, so tweaking prong thickness or base depth later would simply require changing one value. Grouping these features into a single component kept the browser organized and isolated future edits.

To make insertion and removal effortless, I added a 0.5 mm chamfer around the front edge of the base, guiding the protector into the outlet without catching on the plate. I embossed “JAYDEN CREATIONS” in a recessed channel around the circumference, both to brand the part and to provide a tactile grip. Finally, I filleted each prong corner by 0.3 mm so they slide smoothly into the socket without scraping paint or plastic. These small tweaks transform a simple plug into a thoughtfully designed safety device.

Material choices and finishes were next. In the Appearance panel, I applied a matte ABS plastic to the entire protector, dialing roughness to a medium level for a slightly grippy feel. The embossed lettering received a glossy finish so it catches the eye and the fingertips in low light. For a future high-end version, I set up a polished-steel material for the base, imagining a designer nursery accessory with metal-printed parts.

Prototyping revealed valuable lessons. Early 1 mm-thick prongs printed in PLA flexed too much, so I increased them to 1.2 mm and reprinted. Quick insertion tests on outlet mockups confirmed a firm hold without excessive force, and the embossed grip made one-hand removal a breeze. With those adjustments locked in, I knew the design was ready for real-world use.

This project reinforced the power of parametric constraints for rapid iterations and the importance of fillets and chamfers in user-facing parts. Moving forward, I plan to explore color-coded versions for different rooms, add a child-alarm clip that triggers a soft beep if prongs are pulled halfway out, and bundle the protectors with a matching screwdriver handle for effortless installation. What started as a simple safety cover evolved into a lesson in human-centered design, where CAD precision meets everyday usability.