Manufacturing Selection Processes

Quantity of Produce

Of the population in the UK are aged

which is 10 million people.

65 and above

Average production in the first year would be

Component

Material

2% of 100,000 = 2000

Number per Annum

Does not require a uniform wall thickness, but the thinner the cheaper it is, so wall thickness of mould would be

How the product is Assembled:

Injection Moulding

Tooling cost much greater than other processes

Quick manufacture times, large quantity

Strong, able to withstand large amounts of weight

Not brittle, high rigidity

Much cheaper tooling costs

Resistant to water degradation

Slow manufacture times, small quantity

Rotational Moulding

Product can be created as one part, though

it be hollow, varying wall thickness arent a
problem

High aesthetic qualities

3mm.

The main pole will be able to slip into the connected part
with a transition fit, however to make sure the two parts are
secure they will be welded together by a machine
The handles will be securely in place with spiral pins that
will be assembled manually. These will be a transition fit so
should not fall out while still allowing the handle to rotate
45 deg
Magnets and ferrule will be glued into place by a precision
machining to make sure they are in the in the correct place.
The finishes on each part will be done before the product is
assembled

Manufacturing

Cheap costing

Part has to be split into 2 half, undergoes large amount of stress

+/- 0.21mm when have to considered in the holes

The CAD model given to manufacture will be

shelled and then covered over in rotational process,
all inside edges have been filleted

Connecting Part - metal injection moulding, made

from Aluminium. Finish: Brushed matte surface

Requires draft angles on all sides of mould with no undercuts

Easy to form and mould

are

Spiral Pins - imported, made from carbon

steel. Finish: As machined

Process Selection

Electrical and thermal insulator

Retractable pins will be used on the front face for magnets and also
on the bottom where there is a cut through for a rotational mechanism. It will be a transition fit with for the pins, tolerances on pins

Magnets- imported, made from

iron. Finish: As machined

Rubber ferrule
Natural rubber
2000
Adjustable pole Aluminium
2000
Handle 1 ABS 2000
Handle 2 ABS 2000
Connecting part Aluminium
2000
Spiral pin
Carbon Steel
4000
2mm x 2mm
Iron
24000
magnets

Qualities required of material

2 deg.

Outside edges have a draft angle of

to allow it to
be extracted from the mould without affecting the design

Pole - metal injection moulding, made from

aluminium. Finished: Brushed matte surface

100,000 people.

Rotational Moulding the mould needs to be de-

For
signed in a specific way:

The final mould will be covered and hollow

Handle Parts - rotational moulding, made from ABS.

Finish: Spray painted matte black.

In the aging population 10% use walking sticks and other mobility aids =

10 million

DFMA for Looped Handle

This product is a walking stick that can be easily assembled to a seat. The handle held in place by magnets, it can be folded
down to provide a stand to rest upon. The big handles and easy mechanism make this product appropriate for the user group
Ferrule - Injection moulding, made from natural
rubber. Finish: As machined.

Lucie Simpson

Also all sharp edges have been filleted as inter-mate

faces are hard to manufacture in this process. The
fillets are of varying degrees

SP1 - C1

Surface finish on this part of the product will be

. The product would then be spray painted with
a matte finish. Primarily the colour will be black on the outside and a brighter colour on the inside show
where the seat is.

Cost of part

Retractable pins easy to include in the mould

Recyclable
Doesnt wear away over a short period of time

Tooling costs much less than injection moulding

ABS

Materials

1. Able to be
molded in complex shapes
2. Coloured
easily
3. Very tough
and resilient
4. UV and heat
resistant
5. Good insulator
5. Very stiff, so
retains shape
6. Costs 1.64 1.81 GBP/kg
7. Weather resistance
8. Resistant to
corrosion
9. Smooth surface finish
10. Recyclable

PVC

1. Rigid but not

very tough
2. Can be stiff
and flexible
3. Brittle
4. Good insulator
5. Long-life
expectancy
6. Higher density than other
polymers
7. Costs 0.89 0.93 GBP/kg
8. Easy to
mould
9. Lightweight
10. Recyclable

PE

1. Easy to
mould and
fabricate
2. Easy to colour, large range
3. Low
strength/stiffness
4. Lightweight
5. Good wear
resistance
6. Excellent
stress and
crack resistance
7. High expansion coefficient
8. Costs 1.10
-1.22 GBP/kg
9. Poor weather
resistance
10. Recyclable

ABS will be used

Blow Moulding

Poor surface finishes

Negative environmental impact
Creates hollow parts, limited asymmetry

Rotational moulding will be used

Why I picked this method...

Cheaper than injection moulding with units being the same quality
Creates water tight products with no sharp edges
Product hollow with all outside areas filleted so very smooth
Positives: Design flexibility, low costings, no waste materials, inserts are easy to accommodate
Negatives: Long manufacture time, more expensive material costings, ribs difficult
to mould.

Process...

1. Fill a hollow mould with a

quantity of powder resin
2. The mould is then heated
at high temperatures in an
oven

Spinning around
allows resin to go to all
parts of mould.

3. It is bi-axially rotated as
the polymer melts and coats
the inside of the mould.
4. The resin in then cooled in
a cooling station
5. When the resin is sufficiently cooled and can retain
its shape it is then unloaded

LOAD -UNLOAD STATION

COOLING STATION

Mass - 111.57 grams or

0.11157 KG

Evaluation

Material cost 1.64 - 1.81 per KG

0.19 - 0.21

Material cost for part -

2000 units to be produced

Tooling costs - 875

(0.44 per part)

Production cost per hour -37.33

(0.019 per part)

Total cost per unit: 0.65 0.67

Total Cost of production (2000 units) : 1,300 - 1340

ABS Rotational Moulded part - cheaper tooling costs than

injection moulding so saving money = cheaper product
Rotational Moulding is an environmentally friendly process
and ABS is an environmentally friendly material
Longer manufacture times for cheaper cost, this is appropriate for the first year of manufacture as volume wont be
as high, may need to be revised if product sells well
Assembley is simple so it is quick for manufacture and can
be understood by the user if there are any problems. Also
limited parts lowers chance of malfunction