Final Project Report

Bottle Cap Opener

Bradlee Speirs, Jingshuai (Frank Guo), Daniel Cox, Faisal Alqudairi, Tyler Smisek

6/2/2017
Our process: Daniel, Frank, Fisil manufacturing team: 3d printing mold form and pouring
plaster. Tyler, Bradlee report team, finishing, documenting.

Solidworks render of final product

3d Printing
1. Create the mold form that should include the bottle opener blank as an outline for
positioning in the mold.
 Solidworks model of the handle

2. Cut the mold form in halves and print each half separately.
3. Save mold form halves as a stl. File
4. Consult 3D printing booklet in metrology lab for 3D printer operation Detains.

Cutting Mold Box

1. Create a SolidWorks model for the two pieces (ends and sides) of the mold box.
2. Allow for approximately 1 around perimeter of mold form.
3. Create part drawing for the pieces that need to be cut and save the file as a DXF. File
Export as DXF. Save a copy, click green check.

DXF file (make sure to click the green check)

4. Put all pieces in single drawing
5. Find a shop mentor to help operate the laser cutter.

Solidworks Drawing Mold box

Laser cutting inch wood for mold

 CNC cutting out stock

Hole punch
1. Put the Bottle opener blank in the punch and apply punch force until punch Breaks
Through.
2. Allow punch to retract and Punch second hole
3. Reposition punch and repeat process
 Hole punch using drill press method

Finished product bottle opener metal

Pouring Plaster
1. Use clamps to hold the box together (we used tape which worked just as well)
2. Insert the mold form into the box
3. Pour an appropriate amount of plaster into a mixing container and add water (ratio is
2p:1w)
4. Thoroughly mix plaster using stir stick until it is an even constancy
5. Pour wet plaster mixture into mold box
6. Gently shake table to remove bobbles from plaster
7. Repeat this step twice to make two mold halves

Mold form

Pouring The Urethane

8. Insert bottle opener blank into mold, fig 12.
9. Close mold and clamp two halves together using board (sides of the mold box work well)
to distribute clamp force, fig 13.
10. Mix plastic to specified ratio
11. 100 part A: 30 part B by mass
12. Total amount needed is roughly 110% of handle volume.
13. Use vacuum chamber to remove gas from mixed urethane, fig 14.
14. -place , mixed urethane in vacuum chamber
 15. -place lid on chamber
16. -power on vacuum
17. -wait until bubbles have stopped forming
18. -power off vacuum
19. -use valve to release pressure
20. - The working time for the urethane is 15 minutes
21. Pour Urethane into mold

Project Assessment
Our project consisted of four main sections. The first section of creating the 3d handle

was the most difficult because we wanted to implement a unique design while keeping the

project within the time allotted. After finalizing the 3d model of the handle, handing it over to

the 3d printer was, again, difficult because of the machines system setup. Before printing the

design, we had to level the platform and continue to do a trial and error print for a couple of

processes. After about three trials we decided to switch to the maker bot printer because the

system was faster to use. Once we completed the 3d print, we went over to computer lab to

produce dxf files for the box mold. This process was straight forward and could have been

completed along with the 3d printed part if we delegated out those different tasks. Once we

finished with the laser cutting process we immediately started on pouring the plaster so that

we didnt waste any time. We had issues pulling the 3d printed part out with the second mold

because of the solidity of the plaster. Finally, pouring the Urethane was troublesome because

of the mixture process and some problems with the mold breaking apart.
 Fit

The laser cut box and 3d printed part fit flush with each other without any issues. We

had to trim the outside edge of the 3d printed handle for clearance reasons but this required

very little time using the band saw.

Finish

The finish product is not finalized yet because of pouring issues with the urethane. But,

we noticed that the most important part of the process was making sure to document

everything.

Team assessment

This team was excellent in communication but we could have improved on delegating

certain tasks out such as someone performing the 3d printer process, while another group

performed the laser cutting for the mold. We improved our time management after the CNC

cutting process and we broke up into two teams so that one group could work on the report

while another could finish the manufacturing of the part.

Lessons learned/Final project/ Faisal Alqudairi

Individually:
The two personal strengths that I have knowledge in were the Solidswork and it wasnt hard for me to
create the design or the part we wanted to model, Also giving good ideas. Another thing that I had some
experience in was 3D printer and it its a great device to model some design.

Two improvement that I learned how to use new machine like the laser cutter and I used it to both
projects the Kaizen and the final to create what we needed in our design. Also the CNC machine is great
machine to cut the materials.

Team:

The stunning participation between us that provide for us the consolation should take a greater amount
and be a solid group. We aided one another in each venture that made it less demanding to us.
Continuously concentrate on the reason what's more entryway on not aggravate the same confuse once
more. We attempted should differentiate the worth of effort the middle of us uniformly.

Likewise those change we got that making a difference one another it provides for an opportunity
should see the methodology effortlessly. Furthermore on Figure those instruments. Additionally giving
careful consideration of the guide provide for us All the more sure on would our best without any
worries.

Project:

Before all else the last venture wasnt basic with create, Anyhow we finished our best on feel Also
detract the enough occasion when should realize how on start demonstrating. I feel imparting the fill in
What's more asking produced things a great part less demanding. Those change we perceive when we
At last constructed our parts and got acquainted with those machines we utilized. We simply
understood how should sit tight concentrate on those worth of effort that will aggravate the
unthinkable will make could reasonably be expected.
BradLee Speirs
ME 410
Final Team and Project Assessment

Team members assessment: Tyler was good at checking what needed to be done and
help organizing us. He was also good at getting stuff done. He could improve by asking more
questions. Daniel was good at organizing us and coming up with solutions to problems. Danial
could improve by learning to be a little more patient. Frank was good at designing and asking
questions when he didnt understand something. Frank could be better at not distracting us while
were working. Faisal was good at asking questions when he didnt understand something and he
was good at helping when asked. He could improve in speaking up when he had an idea or when
he wanted to do something in the project. I was good at helping when needed and coming up
with ideas. I could improve by speaking up more on my ideas and by being a little more
proactive.

Team assessment: We work well as a team. We were good at organizing and getting stuff
done. We were also good at coming up with solutions when problems arose. We could work on
making sure everyone was a little more involved. We could also do better on communicating on
where were at and what happened when things went wrong.

Project assessment: The project was fun. However, one way to improve would include
giving us more time so we can recover when things go wrong. We had problems with the 3D
printer not wanting to print right and then problems with the mold cracking and then something
happened where our mold broke with the polyurethane in it (like someone dropped it when we
werent their). Another thing is some of the instructions (for the process) were a little unclear and
was a little confusing until we got to the 3D part. We almost printed a part that did not account
for the board thickness because we miss understood the process. One good thing about this
project is that we all get some experience with the CNC mill and how to code for it. Another
good thing is that we got experience with the 3D printer and laser cutter. Also learning how
molds can be made was nice since Ive never seen how molds are made.
Daniel Cox

One strength of the team and the project was that we started early and the project made you start
early. Many of the processes like letting the handle set up and the 3d printer took a lot of time that we
could not rush. This meant we had to be creative on how we used our time and either work on other
parts of the final project or work on other things. This is something that the team did. We worked on the
final project as much as we could then most of use used the other time to work on other things.

Another strength was this project forced us to be really lean when we were planning what we were
doing. This meant that any disagreements whether it be creative or personal need to be solved quickly.
This is something that our team did. I wanted to do so something different to what the team wanted to
do. Everyone respectfully listened and liked the idea but due to time constraint it was decided to do
something simpler than my idea. This was one of the smoothest team that I have worked with.

One improvement to the project would be more time for the project or less processes that could not
have been sped up. Where I did like the time constraint but this meant we could not do complex things
or try prototyping different designs. Also if the something happened to the parts that took a long time to
produce then there would be little that the team could do with in a short time frame. The 3d printer and
letting the handle dry took some much time that I would change to a project that didnt have those
some teams could have more flexibility to try more things or I would have more time to this project.

Another improvement would be to have enough the material to make the project and to mess up on
hand. While making the molds the plaster material ran out a couple of times and this slowed down the
process. This only compounded the short amount of time. The material to make the handle also set up
really quickly and could not be poured in all the molds so this took some time to fix. I would say to have
the material and process down before people started manufacturing

As for my team I could not think of an improvement. We all worked hard and well together. This may
have change if we worked on a longer project but for the short time together I am extremely happy.
Tyler Smisek
Individually:
The two personal strengths that helped the team was solidworks and communication. Knowledge of
solidworks helped with making the handle and box design for the laser cut out.

Two improvements that I can work on are using the 3d printer more efficiently and I would also like to
know a little more about how to use the laser cutter because we didnt really go in depth on the
software.

Team:

I think the team worked well together for each step in the process. We improved on communication and
delegation once we began working on the 3d printed mold. After noticing the importance of teamwork
and cohesion we decided it would be best to split into two teams so we could spread the load of work
across the group. This helped a lot with writing the report and kept everyone working on something
instead of having one person do all the work.

Everyone contributed during the entire project which made the process very fluid and we ran in to very
few errors.

Project:

I feel like this project taught us a lot about using the 3d printer, laser cutter and the steps to pour a
successful plaster mold. One improvement to the project would be to have a video tutorial for each
process before having the teams start. This would make it easier to visualize what we are actually doing
and get rid of any confusion on the procedures.