P18433: Nicaragua Bottle Upcycling Product Design and Manufacturing
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Subsystem Build & Test

Table of Contents

Team Vision for Subsystem Level Build & Test Phase

Phase 6 Team Plan + Milestones (online)

In this phase the team hoped to finalize a lot of the building and get ready for integration and debugging of the systems. This was to be supplemented with completed design packages for the structure build, the mold design and measurement and control electronics for the system. Whilst putting the heating together was to be put off for a couple more weeks until we had a better plan for integration. On the building side we wished to finalize our test mold, and mold design. With the objective of actually running some preemptive tests. The welding of the structure was also to be finished, this was unfortunately not completed as our team member Pierce got hospitalized, leading to noticeable delays on the structural side of things.

We managed to test our mold, creating a sheet of plastic that fully melted on the one side where even heating was applied. The other side of the mold was not heated correctly thus the plastic did not melt. The final mold design was changed to have the ability for easier extrusion and cooling. As well as resolving some of our main machining concerns. The structural design was redefined and updated, and a design and build package was created to start getting the welding and building going. The parts for the structure were machined and cleaned up, prepared for assembly and welding. The heating system has been bench-marked and after some budget wise problem solving seems to be ready for ordering. A lot of risk analysis was undergone this phase leading to a safer system design, which we believe to have a greater probability of success.

Subsystem and Testing Equipment Build

Welded Frame Assembly Drawing
Mold Drawings

This new mold design was made with the idea of extracting and cooling the mold with greater ease. With another added advantage of much better manufacturing capabilities, as the previous iteration of the design would have been extremely demanding in regards to machining and building. This design involves a three piece mold with alignment systems and an aluminium core.

Machining

Car Jack Hole Drilling

Car Jack Hole Drilling

Tube Slot Cutting

Tube Slot Cutting

Steel Tubing Cuts

Steel Tubing Cuts

Steel Tubing Cuts

Steel Tubing Cuts

Test Results Summary

Plastic Melting Test #2

Tools:

Melt Test Setup

Melt Test Setup

Melt Test Setup

Melt Test Setup

Procedure:

Opened Mold

Opened Mold

Plastic- Bottom Side

Plastic- Bottom Side

Plastic- Top Side

Plastic- Top Side

Takeaways & Results:

Thickness Measurement 1

Thickness Measurement 1

Thickness Measurement 2

Thickness Measurement 2

Risk and Problem Tracking

Risk Assessment

Risk Assessment Screenshot

Risk Assessment Screenshot

A working Risk Assessment file can be found here. The primary source of risk mitigation has come from better understanding the heaters that we will be purchasing:

However, an additional risk was added concerning the cost of the heaters:

Risk Chart

Risk Chart

Problem Tracking

Problem Tracking Screenshot

Problem Tracking Screenshot

A working Problem Tracking file can be found here.

The primary problems that are being dealt with are:

Benchmark

Strip Heaters

Strip Heater Benchmark

Strip Heater Benchmark

We have contact multiple companies for assistance with Strip Heaters. Many of which have offered expertise and input into what could work with our system. However, few come with all the parts we need and fall bellow the $300 price range. Wattco has presented an offer to provide us with heaters for free in exchange for acknowledgement in our project but we have yet to get a full quote from them. We may purchase from the cheapest vendor for now in order to meet our deadline but continue to pursue the Wattco offer for the opportunity to get more heaters later on and for the next team.

Functional Demo Materials

Plans for next phase

Home | Planning & Execution | Imagine RIT

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Build & Test Prep | Subsystem Build & Test | Integrated System Build & Test | Customer Handoff & Final Project Documentation