Bracket Design Process
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The document describes the design process for a wall bracket to securely attach a child safety gate to the wall. It goes through the phases of identifying problems with existing gates, concept development and prototyping. An initial prototype was created through rapid prototyping to test the design. The final design will be manufactured using injection molding, which requires creating a mold. The document discusses the injection molding process and provides a basic cost analysis.
Bracket Design Process
- 1. Materials and Processes (CD220)Wall BracketFebruary 27, 2009Created by: Erik JalowyInstructor: Mr. Jankowski
- 2. Begins with an idea that develops from a need.Design PhasesProduct design involves the following phases:ConceptPrototype and testingDesign evaluation and reviewManufacturing review2/27/2009CD220 - Materials and Processes2PRODUCT DESIGN SEQUENCE
- 3. Child safety gate has no secure connection to the wall while in place.
- 4. Gate is designed to only wedge between two surfaces.Issues:Gate needs to be adjusted regularly.
- 5. Connecting points tear up the paint & drywall.
- 6. Gate can be pulled out of place easily and fall onto the child.2/27/2009CD220 - Materials and Processes3PROBLEM IDENTIFICATION
- 7. 2/27/2009CD220 - Materials and Processes4PROBLEM IDENTIFICATION
- 8. Need a way to attach gate to wall.
- 9. Searched manufacture for hardware.
- 10. Would need to buy a more expensive gate.Create wall bracket to fit the gate.Take necessary measurements
- 12. Model part to be created for testing2/27/2009CD220 - Materials and Processes5PROBLEM INVESTIGATION
- 13. 2/27/2009CD220 - Materials and Processes6CONCEPTUAL DRAWINGS From hand sketches to CAD drawings2/27/2009CD220 - Materials and Processes7SELECTED CONCEPTDETAILED BRACKET DRAWINGASSEMBLY DRAWING
- 14. 2/27/2009CD220 - Materials and Processes8SELECTED CONCEPT2D to 3D
- 16. Looking to cut model out of plastic.
- 17. Submitted 3D CAD model for quotes.2/27/2009CD220 - Materials and Processes9RAPID PROTOTYPING
- 18. Quotes ranged from $30-$178
- 19. Went with the lowest quote from Orange County Choppers.
- 20. Bracket was cut from block of plastic.
- 21. Cut and shipped out the same day.
- 22. First cut out on a water jet made by Flow Jet, then it was completed on a Haas CNC machine.2/27/2009CD220 - Materials and Processes10RAPID PROTOTYPING
- 23. 2/27/2009CD220 - Materials and Processes11RAPID PROTOTYPING*Pictures provided by Orange County Choppers
- 24. Concept model fit well.
- 25. Keeps gate from sliding off wall.
- 26. Dont see any design issues or flaws.2/27/2009CD220 - Materials and Processes12DESIGN TEST & EVALUATION
- 27. 2/27/2009CD220 - Materials and Processes13MANUFACTURINGBracket to be made from Injection Molding.
- 28. A mold would need to be created of the bracket.Advantages:High volume of parts
- 29. Injection molding is commonly automated
- 30. Fine details are easily producedDisadvantages:Mold cost is high
- 31. Low volumes are not recommended
- 32. High initial equipment investmentClamping - Holds mold together, opens and closes automatically.
- 33. Injection - Plastics pellets inject into the mold cavity to form the parts.
- 34. Cooling Liquid plastic cools down and solidifies.
- 35. Ejection Solidified parts are cooled and ejected from the machine.2/27/2009CD220 - Materials and Processes14BASICS OF INJECTION MOLDING
- 36. 2/27/2009CD220 - Materials and Processes15COST ANALYSISCAD modeling of part $85/hr
- 37. Rapid prototyping for part $30 - $200.
- 38. Tooling cost could range from $1,480-$20,000, this is a one-time cost for the mold.
- 39. Aluminum or steel molds can be created.
- 40. Parts made from polypropylene (thermoplastic).
- 41. Set-up & operator charges varies.*Prices based on Epsilon Industries
- 42. 2/27/2009CD220 - Materials and Processes16COST ANALYSISInjection molding cost varies from material, machine time, and man-hours
- 43. Cycle times can improve by adding multiple cavities, and thinner parts.
- 44. Example part with $0.10 material and $1.00 cycle*Prices based on Epsilon Industries