Customer Handoff & Final Project Documentation
Table of Contents
Team Vision for Final Demo and Handoff
During this phase the team attempted to finish and test all subsystems individually and integrated into the final machine. At the end of the previous phase, only the electronics and heating required work for completion, while the structure and compression subsystems were completed and integrated. Testing with the full machine was to be completed and a final product was to be constructed using the three-piece mold. Recommendations for the continuation of this project would be based on the results of the full machine testing.
The team completed the construction of all subsystems and successfully integrated them into the final machine. Two full scale tests were completed, however, the results were not sufficient to accomplish the goals of the project. The resulting test samples did not fully melt as desired and as a result were not able to be vacuum formed into a building product shape. Suggestions for future design teams can be found below.
Our Final Design
The CAD files can be found here.
Test Results Summary
All visual tests passed including machine accepts mold, machine is within desired footprint size, and one mold has been created for use. The more involved tests involving melting tests were not able to run yet as some subsystems are still being integrated, including the electrical and heating.
Tests concerning the temperature of the machine were also completed, but results failed the criteria set by the team. The test required the mold to reach 250 Celsius, but the maximum temperature reached was approximately 150 C.
Tests concerning safety were completed and passed (area of exposed hot surfaces, gas released from the machine, etc.), but additional safety concerns that were not stated in the test plans or requirements, were identified. These can be seen below in the future recommendations.
Tests concerning the cycle time of the machine and variable inputs into the machine were not completed. These tests should be the focus of future teams after the recommended changes to the machine are made.
Our performance vs. engineering requirements can be foundhere.
The test results can be found here.
Images and video of the first and second full tests can be seen below.
Link to the first test video can be found here.
Link to second test video can be found here.
Risk and Problem TrackingAll remaining risks come from the machine not having the heat capacity required to fully melt all of the plastic in the mold. This lead to being unable to mitigate additional risks associated with the removal of the final product from the mold. The remaining risks should be a top consideration for future teams tasked with this project.
A working Risk Assessment file can be found here.
A working Problem Tracking file can be found here.
Feasibility: Economical, Market Analysis
Keep in mind these numbers will change now that vacuum forming has been added as an active step through the supply chain. You should make a new set of assumptions and run a new analysis to determine the required value per hour and how to get there. From our work with this market we can state with a high level of confidence that if you can generate anywhere in the ballpark of $1,000 per month you should be meeting requirements with ease. I would aim to maximize the number of products acquired from each vacuum molding process. As it will probably have greater returns if you produce 4 cups from 1 sheet of plastic than the single sheet of plastic. You will have to get creative with the product to be acquired from the vacuum former.
Final Project Documentation
- Customer Requirements can be found here.
- Engineering Requirements can be found here.
- System Architecture can be found here.
- Pictures through out the build and test process can be found in the Project Photos and Videos
- Final BOM can be found here.
- Manufacturing and Assembly Instructions can be found here.
- Safety Precautions can be found here.
- Operator Manual can be found here.
- Recommendations for future work can be found here.
- The full Drawing Package can be found here. An example drawing sheet can be seen below.