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SafeSource: Formal Design Review

SafeSource: Formal Design Review. Team 3: Robin Davis Meryl del Rosario Joanna Natsios Paul Saindon. Bucket 20 L capacity Head dimple on bottom Stackable for shipping Spigot Lid 4 in. fill port with cap. General Durable Thermoformable material Inexpensive.

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SafeSource: Formal Design Review

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  1. SafeSource: Formal Design Review Team 3: Robin Davis Meryl del Rosario Joanna Natsios Paul Saindon

  2. Bucket 20 L capacity Head dimple on bottom Stackable for shipping Spigot Lid 4 in. fill port with cap General Durable Thermoformable material Inexpensive Product Design Specifications

  3. Thermoforming Process • Heat thermoforming apparatus • Insert mold and plastic • Heat plastic • Turn on vacuum and push mold up into plastic • Cool plastic-mold slightly • Remove mold • Allow for complete plastic cooling

  4. Material Selection- Thermoforming • Thermoplastics • Amorphous • Lower thermoforming temperature • Forgiving of temperature variations • Forms well with wooden molds • Creeps over time under load • Crystalline • No creep, but warpage • Totally stiff until softening temperature is reached • Must be formed around aluminum mold

  5. Our Materials • Requirements: • food grade • UV resistant • cheap • clear/translucent • no reaction with kerosene or NaOH • Polycarbonate (Lexan 9440) • GE Polymershapes • UHMW Polyethylene • McMaster-Carr • ABS

  6. Property Comparison http://www.mcmaster.com/

  7. Design Limitations • Constrained thermoforming size • Draw ratio • Avoiding undercuts • Preventing webbing • Bucket needs to be 20L • 14”x11”x8”

  8. Thermoforming Experience • Wooden mold for lid • Made from scrap using simple tools • Thermoformed successfully • Nearly fits bucket • Observations: Warpage and lack of undercut

  9. Revisions and Returns • A second mold was designed to correct the problems of the first • Fill port added • Triangular feet to improve undercutting Our design process will be iterative! Top View Bottom View

  10. Mold Design: Bucket

  11. Mold Design: Lid • Wood for easy creation • Triangular shape to improve removability from mold • Undercut and feet to provide snap for attaching to bucket. • Biggest challenge: design of fill port cap

  12. Looking Towards Production • Would want a Steel or Aluminum Mold with cooling channels • Increased consistency of parts • Increased rate of production • Longer mold life • Better thermal properties • Develop jig cutting technique

  13. Compressive Testing of 3DP Material • Mold must withstand 15psi • 9 2-inch cubes • 4 cubes w/ new glue, 5 cubes w/ old glue • Tested each direction 3X • Results • Compressive strength greatly exceeds 15psi • Strongest in X-direction, weakest in Z (binding) direction • Stronger when infiltrated w/ new glue

  14. Future Testing • 3-point Beam Bending • ASTM for a ceramic • 0.25” thick • 1.5” long • 3D print specimens in different orientations • Printer problems

  15. Further Investigation • Deformation Mapping • Shrinkage Analysis • Impact Tests • Drop Strength Analysis (ANSYS or ASTM) • Non-Newtonian Flow

  16. Design Variables • Plastic thickness • Tapering • Snap mechanism • Ribbing

  17. Project Timeline • Learn SolidWorks and ANSYS • Create compressive elements on SolidWorks • 3D print compressive elements • Conduct compressive strength tests and 3pt beam bending tests • Determine physical limits of mold geometry 6. Design mold of interlocking parts 7. Print 3D scale models of bucket and lid 8. Thermoform scale prototypes with various materials 9. Choose material for final bucket and lid 10. Make full-sized bucket and lid

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