RPI Storage Box with Removable Dividers

1
RPI Storage Box with Removable Dividers

• Kaleigh Iler Columbia HS
• Nabihah Azhari Troy HS

2
Product Design
3
Product Design
4
Product Strengths

• Allows for easy organization of small items
• RPI logo facilitates school spirit
• Flexibility in design
• Requires multiple MILL processes
• Can be manufactured within budget

5
MILL Processes

• Plastic Injection Molding
• Abrasive Water Jet Cutting
• CNC Machining
• Powder Coating
• Ultrasonic Welding
• Vacuum Forming
• Laser Cutting
• Robotic Assembly

6
Sides

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

7
Aluminum Bottom

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

8
Side Assembly

• Ultrasonic welding
• Fits around aluminum bottom to secure

Bottom View
Top View
9
Corner Pieces

• CNC Machined
• Fits around corner
• Powder coated for finish
• Secured with purchased screws Grainger
  Industrial Supply
• Screw hole 1/16 diameter

10
Dividers

• Plastic injection molded
• CNC machined mold
• 2 Large dividers
• 5 Small dividers
• Large dividers made in two equal pieces and
  ultrasonic welded together

11
Divider Layout
12
Lid

• 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

13
RPI Logo

• Raised RPI Logo vacuum formed
• Cut out by laser cutting
• Attached using ultrasonic welding inside indented
  circle
• Logo raised ½ above lid surface

14
Side View
15
Processes Summary

• Plastic Injection Molding Creates sides,
  dividers, and lid
• Abrasive Water Jet Cutting Creates aluminum base
• CNC Machining Creates plastic injection molds
  aluminum corners
• Powder Coating Colors aluminum base corners
• Ultrasonic Welding Attaches sides, dividers,
  lid
• Vacuum Forming Creates RPI logo for lid
• Laser Cutting Cuts out vacuum formed pieces

16
Alternative Ideas

• Product could be made as a Do It Yourself
  project, with minor design changes
• Technical writing skills
• Different divider arrangements

17
Cost Estimate
Material General Cost Cost per Box Total Cost (400)
Large Mold 500/mold 1.25 500 (1)
Small Molds 250/mold 1.25 500 (2)
ABS Donated Donated 0
Vacuum Form Plastic Donated Donated 0
Aluminum 5.00/lb 0.50 200
Screws 16.00/100 1.28 (8) 512
Powder Coating 5.00/lb 0.88 350
Total ----- 5.16 2,064
18
Any Questions?