RPI Spirit Clapper

By: Gazi Sakib Hudson High Schooland Katelyn Coffey Averill Park High School

Know the Spirit, Live the Spirit

Flickering lights

Shaped like a hockey stick and puck

RPI Colors

Fun facts about the Red Hawks

Processes used:

1. Injection Molding

2. Powder Coating

3. Laser Engraving

4. Ultrasonic Welding

5. Metal Forming

6. Abrasive Water Jet

7. CNC machining

8. Soldering

2-D base and the 3-D cover (hockey stick shaped)

1. 2D base- Abrasive Water Jet (cut out) - CNC machine (switch opening)

2. 3D cover – Abrasive Water Jet (cut out) - Metal Form (to give it some depth)

3. Attach using ultrasonic welding

Circuit and Switch

1. Button Battery2. Wires 3. Slide Switch 4. LEDs

Wires and switches can be soldered to strengthen circuit.

(Alternative) Changeable batteries and custom switch

Clapper1. Puck holder with slots and middle puck (plastic

injection molded)- transparent lumogen dye

2. Two side pucks (plastic injection molded)- red lumogen dye

Clapper

1. Attach pucks and holder (ultrasonically welded)

2. Attach the clapper to base

Why make it?

1) Variation of processes (almost all in MILL)

2) Basic circuitry and soldering(challenging and interesting)

3) Alternative custom switch and circuit design (involved electronics)

Proposed Customs and Design

1. The two outside pucks carry the symbols of RPI (powder coating).

2. The hockey shaped aluminum base is powder coated with black and white stripes.

3. Fun facts about the RPI hockey team are laser engraved on the aluminum base.

1. 1901- The birth 2. 1st NCAA championship in 19542. 38 undefeated streaks3. The legends of RPI hockey– Adam Oates and Darren Puppa (now pro NHL players)

CostMaterial Cost

Plastic $0.00

2 small molds $500.00

LEDs (800 pieces) $73.00

Aluminum $220.00

Powder Coating $85.00

Lumogen Dye $448.00

Copper Wire $12.00

Batteries $160.00

Slide switch $316.00

Total $1,800.00

$4.50 per clapper

Questions?