RPI RPI Storage Box with Storage Box with Removable DividersRemovable 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 Allows for easy organization of small itemsitems

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 identical parts•CNC machined mold•Plastic injection molded•Fit together at corners•Sides 6” long together

Aluminum BottomAluminum Bottom

•Cut by abrasive water jet cutting•Powder coated for finish•1/8” thick

Side AssemblySide Assembly•Ultrasonic welding•Fits around aluminum bottom 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 injection molded•CNC machined mold

•2 Large dividers•5 Small dividers

•Large dividers made in two equal pieces and ultrasonic welded together

Divider LayoutDivider Layout

LidLid

•CNC machined mold•Plastic injection molded•Made in 4 pieces and ultrasonic weld them together•Indented circle in top for 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, Plastic Injection Molding: Creates sides, dividers, and lidand lid

Abrasive Water Jet Cutting: Creates aluminum Abrasive Water Jet Cutting: Creates aluminum basebase

CNC Machining: Creates plastic injection molds & CNC Machining: Creates plastic injection molds & aluminum cornersaluminum 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 It Product could be made as a “Do It Yourself” project, with minor design Yourself” project, with minor design changeschanges– Technical writing skillsTechnical writing skills

Different divider arrangementsDifferent divider arrangements

Cost EstimateCost EstimateMaterialMaterial General General

CostCostCost per Cost per

BoxBoxTotal Cost Total Cost

(400)(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 Form Vacuum Form PlasticPlastic

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?