ITMT 186

Rapid Prototyping Design Project

Shane Holbrook

Date: 11/15/2014

OVERVIEW/ Problem Statement

Below is a series of photos in which will show the initial design I was faced with. The problem is simple:
Design a cheap affordable USB drive that is sturdy, functional, ergonomical, and appealing to all ages. The
problem lies in two places: 1. In the market area which has a high unemployment rate, low population, and
the current jobs available are in coal mines, which are strenuous, and harsh. 2. In the flimsy USB design
below, the USB drive would never withstand the harsh environment if clipped on a keychain for instance.
The problem will be to design a product to adhere to these constraints while making sure the product size
does not exceed 2.25 in length x 1.50 in width x 1.50 thickness.

Usb W/Housing

USB W/Housing Side

USB Housing

USB Housing (Side)

ITMT 186

Rapid Prototyping Design Project

Shane Holbrook
Solution Approach

Date: 11/15/2014

The solution will lie in using affordable ABS Filament plastic, and utilizing a 3D printer as the process of
choice. As due to the size of the community, a bigger mold injection process would cost quite a bit more
per part, due in face of the current population size. So we will use a little of the ABS plastic as possible,
while still making the product as thick as possible, about 0.125 an inch extra on each side, equating to
about 0.625 extra inches in total. Also as opposed to the original, the USB itself will be fully enclosed, with
respect to the prong of the USB being exposed. This will satisfy the durability feature, as well as the
constraints of dimensions, and the constraints of price, which will relate to the process chosen for
manufacturing costing us about $0.05-$0.08 per part produced. This will easily accommodate the 2,078
people, equating to $103.90-$207.80 for the entire community. The next problem to solve will be to make
the product desirable to all ages throughout the community. To target an age group with such a wide range,
I have chosen to simply place a decal on each USB housing on both sides near the USB Prong, and on the
bottom, which will be a decal of the local CBL Semi-Pro Basketball team the Letcher County Miner. We
will also be making the design more ergonomic by placing bump-like grooves on the top, to make
insert/ejections easier. I feel as if all requirements were met with this design, as it isnt something flashy, it
will withstand the elements, as well as be appealing to the community in which the business will be
starting, by utilizing an already set sports organization involved in community expansion, involvement, and
progression as that of the Letcher County Miners.

Design Process Model

My design process began concurrently with the ideals from the book, Engineering Design by Rudolph
J. Eggert. (Eggert, R. (2010). Engineering design. Meridian, Idaho: High Peak Press. September
26.2014. pgs.6-7.) In which Eggert focuses on, Form is the solution to a design problem. In which I
have based many designs from in the past. The step process in which I followed is quite simple:
Formulating: In which functional requirements are realized, determine constraints, set performance
targets. Then basically preplanning a new solution to this set of problems.
Generating: In which alternative forms are made (shape, configuration, size, material, manufacturing
processes). This is basically where concepts are drawn up to solve the idea.
Analyze: Predict performance/behavior. Which is basically taking all mathematical data and
determining if the product will work as needed by the customer and satisfy all functional requirements.
(IF NEEDED AN ADDITIONAL STEP OF REDESIGN CAN BE USED HERE WHICH STARTS
BACK AT GENERATE, IN ORDER TO RESELECT AN ALTERNATE CONCEPT WHICH WILL
SATISFY THE FUNCTIONALITY OF THE PART.)
Evaluate: Where the performance of each design candidate is compared and the best design is selected.
To simplify the process in which I have chosen is simple: 1. Come up with a problem. 2. Come up
with possible design solutions. 3. Determine if these work the way we need them to, and is possibly the
best. 4. Take the all the designs that made it this far and compare and contrast to select the best.
I chose this approach due in part to the simplicity of the process. The problem itself is quite simple, I
felt as if this process would force me to continuously turn to my problem, without the knowledge of
physics being a factor, I could only worry about customer satisfaction in terms of my target
customer/city of choice. So with this approach, I was forced to make sure I was following closely to
my basic constraints. Below I have included a write up of my Brainstorming sessions, In which my
overall constraints, conceptualization, and dimensions are listed.

ITMT 186
Shane Holbrook

Rapid Prototyping Design Project

Date: 11/15/2014

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Shane Holbrook
Project Sketches

Rapid Prototyping Design Project

Date: 11/15/2014

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Shane Holbrook

Rapid Prototyping Design Project

Date: 11/15/2014

ITMT 186

Rapid Prototyping Design Project

Shane Holbrook
CAD/ Solidworks Drawings

Date: 11/15/2014

Drawing1-Layout1.pdf

ITMT 186

Rapid Prototyping Design Project

Shane Holbrook

Date: 11/15/2014

USB_HOUSING_ATTEMPT_1_W_AUX_VIEW.xps

Software/ Equipment List

Solidworks
Autodesk AutoCAD
Dial Calipers
Various Computers
I have been using AutoCAD for quite some time, so ease of use is due strictly to familiarity.
I am quite new to Solidworks, so using it in all ways possible and as much as possible, is the best way
to familiarize yourself. I have utilized many facets of the program with this project including, 3D
modeling, as well as the drawing aspects, material placement, and assembly.
The project was quite defined and found myself quite motivated and on track throughout. No need for
anything other than that which was already available to me.

ITMT 186

Rapid Prototyping Design Project

Shane Holbrook

Date: 11/15/2014

Image of your final product

(Shown With ABS Plastic Filament & Mock USB Drive separated from USB Housing)

ITMT 186
Shane Holbrook

Rapid Prototyping Design Project

Date: 11/15/2014

Here we can see the finished result once printed and assembled.

ITMT 186

Rapid Prototyping Design Project

Shane Holbrook

Date: 11/15/2014

Data Collection and Verification

ORIGINAL HOUSING INNER DIMENSIONS:

Thickness: 0.25
Width: 0.50
Length: 1.187
USB Inner dimensions: (Hidden part inside of old housing)
Thickness: 0.250
Width: 0.625
Length: 0.687
New Housing Inner Dimensions:
Thickness: 0.2500
Width: 0.6250
Length: 0.6870
New Housing Outer Dimensions:
Thickness: 0.500
Width: 0.8750
Length: 1.8120
Printed housing Inner Dimensions:
Thickness:0.2500
Width: 0.6250
Length: 0.6872 (This could be do to failure to properly remove all structural buildings by the printer)
When compared to the drawing and printer, you can see that the accuracy of the printer is 99% if not as
close to exact as possible. Imperfections could arise based on several factors however, being structural
buildings by printer not being removed during assembly as such as we have seen with this design.
Printed Housing Outer Dimensions:
Thickness: 0.500
Width: 0.875
Length: 1.8120
Process Used: 3D Printing
Volume in^3: 0.7927500000000001
Material used: ABS Plastic Filament
Cost of Material Per Part: $0.06-$0.10 (Which Equates to being 0.7927 x $0.06 ($0.10) = $0.05-$0.08)
Tensile Strength: 6,500 psi
Compressive Strength: 6,750 psi
https://www.botfeeder.ca/abs-vs-pla/
http://3dprintingsystems.com/faq/

City of Production Research

City Of Choice: Whitesburg, Kentucky

Population: 2,078 http://www.census.gov
Unemployment Rate: 11.5% http://www.wkyt.com/home/headlines/277075521.html
1,600 people, 642 households, and 412 families residing in the city. The population density
was 516.9 people per square mile (199.3/km). There were 733 housing units at an average
density of 236.8 per square mile (91.3/km). The racial makeup of the city was 96.19% White,
0.62% African American, 2.62% Asian, 0.06% from other races, and 0.50% from two or more
races. Hispanic or Latino of any race were 0.56% of the population.

average salary for jobs in Whitesburg, Kentucky is $28,408

http://www.cityofwhitesburg.com/ via http://en.wikipedia.org/wiki/Whitesburg
%2C_Kentucky
http://www.simplyhired.com/a/local-jobs/city/l-whitesburg,%20ky

Conclusion

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ITMT 186

Rapid Prototyping Design Project

Shane Holbrook

Date: 11/15/2014

Although this is the second class that I have done a laboratory report document as this, I have learned much about
the Solidworks software, as it is still new to me. I find it much easier to relate, and to find ways to accomplish my
goals, if presented in the form of something exciting.
The overall objective was completed, I was able to complete the design in the allotted time, and with the dimension
constraints I was presented with. The printer was amazingly accurate and the objective of the printing was also
successful.
It was very relevant, in regards to the software, (Assemblies, basic drawing tutorials), and previous laboratories, as
well as the information covered in the book as well.
The only thing I would have changed in the activity would be the USB sizes. As this can vary upon person to person,
I would give someone a basic dimension for a single USB, that way everyones design would be to solve a
centralized problem, which would still have variance from person to person.

Technical Article Correlation

Kolberg, E., Reich, Y., & Levin, I. (2014). Designing winning robots by careful design of
their development process. Research In Engineering Design, 25(2), 157-183.
doi:10.1007/s00163-014-0171-y
o

The basic thing I took from this project was the process itself. How should you attack the problem in order
to come to the solution. In the article listed above, the authors goal was to take high school students and
implement a robotics design process, in which would achieve better improvements, robustness, as well as
turn students into better designers. Like this project, without a sturdy process, you are doomed to fall face
first, and end up lost within all the knowledge.

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