RPI Storage Box withRemovable DividersRPI Storage Box withRemovable Dividers
Kaleigh Iler: Columbia HSKaleigh Iler: Columbia HS
& Nabihah Azhari: Troy HS& Nabihah Azhari: Troy HS
Product DesignProduct Design
Product DesignProduct Design
Product StrengthsProduct Strengths
Allows for easy organization of small itemsAllows for easy organization of small items
RPI logo facilitates school spiritRPI logo facilitates school spirit
Flexibility in designFlexibility in design
Requires multiple MILL processesRequires multiple MILL processes
Can be manufactured within budgetCan be manufactured within budget
MILL ProcessesMILL Processes
Plastic Injection MoldingPlastic Injection Molding
Abrasive Water Jet CuttingAbrasive Water Jet Cutting
CNC MachiningCNC Machining
Powder CoatingPowder Coating
Ultrasonic WeldingUltrasonic Welding
Vacuum FormingVacuum Forming
Laser CuttingLaser Cutting
Robotic AssemblyRobotic Assembly
SidesSides
•Two identicalparts
•CNC machinedmold
•Plastic injectionmolded
•Fit together atcorners
•Sides 6” longtogether
Aluminum BottomAluminum Bottom
•Cut by abrasivewater jet cutting
•Powder coated forfinish
•1/8” thick
Side AssemblySide Assembly
•Ultrasonic welding
•Fits around aluminumbottom to secure
Bottom View
Top View
Corner PiecesCorner Pieces
•CNC Machined
•Fits around corner
•Powder coated for finish
•Secured with purchased screws[Grainger Industrial Supply]
•Screw hole 1/16” diameter
DividersDividers
•Plastic injectionmolded
•CNC machined mold
•2 Large dividers
•5 Small dividers
•Large dividers made intwo equal pieces andultrasonic weldedtogether
Divider LayoutDivider Layout
LidLid
•CNC machined mold
•Plastic injectionmolded
•Made in 4 pieces andultrasonic weld themtogether
•Indented circle in topfor logo
•3/16” Thick
•Indented 1/16”
•3 ¼” Sides
•3/4” Overlap
RPI LogoRPI Logo
•Raised RPI Logo vacuum formed
•Cut out by laser cutting
•Attached using ultrasonic welding inside indented circle
•Logo raised ½” above lid surface
Side ViewSide View
Processes SummaryProcesses Summary
Plastic Injection Molding: Creates sides, dividers, and lidPlastic Injection Molding: Creates sides, dividers, and lid
Abrasive Water Jet Cutting: Creates aluminum baseAbrasive Water Jet Cutting: Creates aluminum base
CNC Machining: Creates plastic injection molds &aluminum cornersCNC Machining: Creates plastic injection molds &aluminum corners
Powder Coating: Colors aluminum base & cornersPowder Coating: Colors aluminum base & corners
Ultrasonic Welding: Attaches sides, dividers, & lidUltrasonic Welding: Attaches sides, dividers, & lid
Vacuum Forming: Creates RPI logo for lidVacuum Forming: Creates RPI logo for lid
Laser Cutting: Cuts out vacuum formed piecesLaser Cutting: Cuts out vacuum formed pieces
Alternative IdeasAlternative Ideas
Product could be made as a “Do ItYourself” project, with minor designchangesProduct could be made as a “Do ItYourself” project, with minor designchanges
–Technical writing skills–Technical writing skills
Different divider arrangementsDifferent divider arrangements
Cost EstimateCost Estimate
MaterialMaterial
General CostGeneral Cost
Cost per BoxCost per Box
Total Cost(400)Total Cost(400)
Large MoldLarge Mold
$500/mold$500/mold
$1.25$1.25
$500 (1)$500 (1)
Small MoldsSmall Molds
$250/mold$250/mold
$1.25$1.25
$500 (2)$500 (2)
ABSABS
DonatedDonated
DonatedDonated
$0$0
Vacuum FormPlasticVacuum FormPlastic
DonatedDonated
DonatedDonated
$0$0
AluminumAluminum
$5.00/lb$5.00/lb
$0.50$0.50
$200$200
ScrewsScrews
$16.00/100$16.00/100
$1.28 (8)$1.28 (8)
$512$512
Powder CoatingPowder Coating
$5.00/lb$5.00/lb
$0.88$0.88
$350$350
TotalTotal
----------
$5.16$5.16
$2,064$2,064
Any Questions?Any Questions?