Preliminary Detailed Design
Team Vision for Preliminary Detailed Design Phase
Create detailed Bill of Materials for the concept product selected: Engineers, by 11/6 It was too early to complete this, so we will have to pursue this in the next design phase and complete by 11/23 Continue initial prototyping, taking into account feedback from our Phase III Review: ID’s and possibly Engineers, by 11/11 Finish drawings in Autodesk Fusion 360: Engineers, by 11/21 Develop flow charts for each part of the manufacturing process: Engineers, by 11/22 Visit Harbec for specific process ideas: Engineers, by 11/23 Create and execute test plans for our product ideas: Engineers, by 11/25 Create Functional Architecture for each finalized product, by 12/1 Continue finalization of designs and process flowcharts: All, by 12/2 Continue to assess and mitigate our risks: All, by 12/7
- The breadfruit shredder designed by P15482 was tested to see shredding capabilities.
- Tested fabrics were goodwill surplus.
Subject Matter ExpertsWe are currently in contact or seeking out the following subject matter experts.
- Randy Dohne, Goodwill International
- Brian M, Fiber Conversion
- Bob Bechtold, Harbec Plastics
- Hannah, Textile Engineer
- Manually sort by type and color -> roughly shred -> injection mold pieces of fabric -> sell to a school
- Manually sort by type -> fully shred to individual fibers -> use shreds as stuffing -> sell at a retail store
Shred Fibers and Mix with Epoxy-like Substance
- Different types of material can soak up different amounts of resin
- Cotton tends to soak up more than polyester
- Need to create a base model to be able to use the fabrics
- Fabric is stretched out to wrap model
- Fabrics have different ways to stretch - not at all, 1-way, 2-ways
- Once resin layering starts, it can take up to 72 hours for each layer to dry
- After a product is made, the fabric could not be reused since it hardens when it is mixed up with the resin
- Harmful effects - both environmental and physical
- Inhalation Dangers
- Can irritate the respiratory tract
- Cause nausea and suffocation in prolonged exposure
- Worse effect if inhaled in an enclosed space
- Swallowing Dangers
- Can cause stress in internal organs if vomit is produced
- Inflammation Risks
- Needs a special cool, dry place to be stored
- Exposure to air, sunlight, or significant levels of heat can result in fire
- Skin Damage
- Can aggravate the skin if in contact, resulting in skin rashes and redness
- Any clothing that comes in contact with the chemical should be thrown away
- Eye Damage
- Can be an extreme irritant if accidental splashes come into contact with the eye
- Safe Removal
- If there is a leak, the area should be well ventilated before trying to remove the chemical
- Resin, like all other chemical materials should be disposed of in strict adherence to state regulations
Injection Molding Synthetic Fibers
- Synthetic fibers such as polyester and nylon are thermoplastics and therefore they can be recycled into their original state.
- The shredded clothing is loaded into a hopper which contains a barrel and screw that moves the material.
- As the material moves down the barrel, heating coils melt the material into a liquid form.
- Once the liquid reaches the end of the barrel it is pushed through a die that forms the diameter of the final pellet.
- Once the extruded form leaves the die it is fed through a water bath to cool.
- The extrusion then exits the water bath and enters the cutter where it is cut to a specified length
- The shape of the pellet is determined by the size of the die opening, the speed of the feed, and the length at which it is cut.
- The final pellets created by the above process can be used to mold an array of products.
- An injection molder functions the same way as the pelletizer except that it injects a specific amount of liquid into a mold rather than a continuous stream through a die.
- Size of the final product is limited by the size of the machine and the injection rate.
Production of Stuffing
- Overall simple process
- Uses more manpower and will very likely employ more people (one of Goodwill’s goals)
- Complex and expensive machinery
- Will require both the shredding process and re-spinning process
48 hour cycle time to spin all of that yarn
To view the information on this page in presentation format click here.
To view our risk management sheet click here.
To Erin's personal vision for the project click here.
To Valeria's personal vision for the project click here.
To Corey's personal vision for the project click here.