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DSID 143 Advanced Materials & Processes | Spring ‘14
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Low Volume Design Phase I
Phase II
Intro & Problem Statement
4-5
Research
6-7
Persona Market Research Comparison Speaker Exploring Manufacturing methods (processes & applications)
8-9
Hot Isostatic Pressing (HIP) Ceramic Coating Filiment Winding New and Emerging technology Wireless power Nano Generators Sugar Batteries
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Phase III
Low volume Manufacturing Methods Compound Wood Bending Dough Molded Compound Direct Metal Laser Sintering
12-13
Ideation Final Direction Exploded View Orthographics
14-17
Vendor Selection Bent Wood DMLS & Injection Molding
18-19
Embroidery Process Abrasive Blasting CNC Engraving Hot Stamping Laser Cutting/Etching
20
OEM Parts & Fasteners
21
Bill of Materials
22
Color Study & Selection
23
Color, Material & Finish Exploded Explanatory View
24-25
Fastening Methods
26-27
Detail Shots
28-29
In context
30-31
High Volume Design Phase I
Phase II
Intro & Problem Statement
32-33
High Volume Manufacturing Processes Injection Molding Woodforce Injection Molding Superforming
34-35
Ideation Final Direction Exploded View Orthographics
36-39
Vendor Selection Injection Molding Superforming
Phase III 40-41
Embroidery Process
42
Bill of Materials
43
OEM Parts & Fasteners Color Study
Color, Material & Finish Exploded Explanatory View
46-47
Fastening Molded-In Speaker & Housing Hardware
48-49
Details
50-51
In context
52-53
44 45
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Float Soundbar
Problem Statement | Low Volume Design The premise of this project was to expose, and familiarize us with advanced materials and processing methods. These methods were then applied to the theoretical production of a low volume home speaker system. Float appeals a narrow target market due to its use of new and emerging technology as well as its expensive and intricate means of manufacturing. It is intended to fully leverage all aspects of tooling, material capabilities, authenticity and craftsmanship to yield a uniquely aesthetic design.
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Research
Phase I | Persona | Speaker Model Philips HTL9100
JBL Cinema SB400
Common Thread Speaker Design
LG NB4530A
Sonos Playbar
• Wireless HD Audio • Audio Decoding: Automatically transforms abrupt high decibel sound waves that are often affiliated with certain television commercials. • HDMI Inputs range from 3-5 • Bluetooth accessible through phone, tablet or computer. • External audio connections (MP3) • 5.1-7.1 channel audio processing • External Subwoofer
Donavon Frankenreiter
Yamaha YSP-2200
Occupation: Professional Musician & sponsored Surfer
Persona
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Income: $125,000+ Donavon is a professional guitarist and an active waterman who shares a deep passion for music. If he’s not on tour or splashing around, you might find him getting down time with his friends and family. Donavon is looking for a new home theater sound system which will provide crisp, deep, surround sound. He is a simple man with a simple taste and doesn’t want anything too obnoxious, yet relies on good quality sound to keep things upbeat.
Speaker Direction
• Slim, low profile • 132 Watt speaker • 16 small adjustable speakers within the bar. • 7.1 channel audio • External Subwoofer • Bluetooth
Speaker & Technology Details Phase I | Research
37-1/8” x 2-3/4” – 3-1/8” (Height adjustable) x 5-3/4” (Center unit), 17-1/8” x 5-3/8” x 13-3/4” (Horizontal) (Subwoofer)
Speaker Dimensions Intelibeam Automated Calibration System
The on screen menu allows you to adjust the angle, beam length and focal length of individual speakers to get the most surround sound out of your room no mater what the shape.
High Crossover
This feature filters the direct frequency between the audio player to send the correct frequency to the correct speaker for superb crystal clear sound.
Intelibeam adjustable sound wave direction example.
What is & Why Bluetooth?
Weighing the Options
Cut away and speaker explanation.
Belkin F8Z492-P Receiv-
Sony BM10 Receiver
Bluetooth is a receiver transmitter that streams wireless audio signals to a specific head unit which is then connected to speakers. This allows the user the ability to connect their phone, computer, or ipod to the speaker’s receivers in order to play their desired music. Where as traditionally, the user would have to manually go back and fourth in order to change songs and playlists. This technology is becoming more familiar and integrated into numerous devices.
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• Slim & more subtle. • Organic shape • 1 less cord involved • Can pair up to 6 devices.
• Limited range to 33 ft. • Needs a wall socket.
• 3oo ft. range • Rectilinear shape • Does not need wall socket. • NFC one touch pairing. • Can pair up to 8 devices.
• Larger an more bulky. • A bit more pricey.
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Exploring Manufacturing Processes Phase I | Research
Hot Isostatic Pressing (HIP)
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Process
Applications
One of the main processes for forming high quality parts. HIP uses powdered materials also referred to as “powder metallurgy”. Heat and pressure in the form of argon or nitrogen gas is applied to the powdered material, resulting in parts that are unperson and high density.
Powdered materials such as titanium, carious steels an, and beryllium can be used. Applications, such as engine turbines, orthopaedic implements, ziconia knife blades, & nitride ball bearings Production is typically less than 10,000 Suitable for producing complex shapes and larger parts.
• High quality parts with no porosity. • Due to the uniform pressure applied to the part their is no areas of weakness. • All micro structures of the component are very structurally sound. • Very efficient use of material • High quality surfacing with certain powders (i.e. ceramics)
• Costly setup. • Shrinkage can be an issue. • Large consumption of energy
A.K.A. Keronite, it is a hardening process that creates an extremely hard, wear resistant ceramic coating that can be used with light metals and alloys. It provides a more environmentally friendly, cost-effective, and precise alternative to hard chroming and plasma spraying. Parts are submersed in an initial layer called “plasma electrolytic oxidation” (PEO). The second coat is more functionally hard, where crystallites are packed into a crystal matrix that covers the entire part.
As a finishing technique it has been used in aerospace, architecture, and aluminum parts such as bicycle shocks.
• Cost effective • The electrolytes used in the process do not contain any environmentally damaging components and can be disposed without treatment. • Keronite is 100% recyclable.
• Number of parts coated at a time is limited by the size of submersion tank.
Filament winding uses a fiber combined with a polymer resin is used to form strong, hallow composites. It involves a fiber that is pulled through a polymer resin bath and then wound around a mandrel or desired mold. This process is repeated until the desired thickness is achieved.
Produces very strong, thin- or thickwalled hallow components, including asymmetrical shapes. Applications such as closed-pressured vessels such as aeronautical components, tanks, and rocket-motor housings. Economical mass-production starts at approximately 5,000 units.
• Produces components with a high strength to weight ratio. • Capital investment cost can stay relatively low by using existing molds or foam molds. • Due to its strength to weight ratio, it is considered a “stealth” material for military hardware. • High operational speeds allow the machines to make the most of energy consumption with large volume production.
• Filament-wound components will always have a pattern, unless post-finished. • Requires a decent amount of energy and toxic composites as well as resins.
Ceramic Coating
Filament Winding
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Hot Isostatic Pressing (HIP)
Pressurized gas & heat are applied in order to densify the object.
Items are place in chamber.
The object is submersed in a electrolyte solution with an added electric current passing though.
As a result, an extremely hard, non porous core and surface is formed.
Next is the functional hard layer where hard crytallites are packed into a crystal matrix.
Ceramic Coating A thin layer is formed in the process called “plasma electrolyic oxidation� (PEO).
The fibers are pulled through a polymer bath where the drum coats each one with resin.
This matrix covers the entire part and completes the hardening process.
The resin acts as a glue to keep the fibers in the desired shape. Once cured, the part can be removed.
Filament Winding
Fibers are unwoven from several reels at a time.
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New & Emerging Technology Phase I | Research
Wireless Powered Guitar Pedals
Technology
Applications
How soon?
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Los Angeles-based F-Pedals has developed a system that merges vintage analog goodness with modern wireless power transfer technology. The pedals are placed on a strip which provides a steady flow of power via magnetic induction technology. The power strip that provides the source energy is also cordless and can be used for up to 20 hours. until needing to be recharged.
Electric Nano clothing
Sugar Batteries
Researchers at UC Berkeley are perfecting microscopic fibers that can produce electricity from simple body motions such as bending, stretching and twisting. The more vigorous the motion, the more power can be harvested. It would take about 100,000 fibers to produce enough power for an electrical watch and 1 million fibers to generate enough current to power an iPod. However, a bundle of 1 million fibers would be only about the size of a grain of sand.
Researchers at Virginia Tech have developed a battery that runs on sugar and could one day replace traditional batteries with ones that are cheaper, refillable and biodegradable. The fuel cells would combine the maltodextrin from the sugar with air to generate electricity. Since the battery is refillable, more sugar can be added to it like filling the gas tank of a car.
• Useful for any device that is dependant on a continuous power. • From charging small devices on a counter top to charging your car in the garage. The applications are near limitless
• Potential for a fairly large, new market in the outdoor’s world. Enabling people to travel further and more-often, while being less dependent on traditional sources of energy to charge their electronic devices.
• Any battery operated device such as smart phones, tablets, video games even transportation vehicles.
F-Pedals claims their effects pedal will be on the market in less than two years and have already begun manufacturing. More complex objects such as phones and cars could be between 3-5 years.
• Could be on the market between 3-6 years depending on how cheaply the nano-fibers can be produced.
In as little as 3 years according to Virginia Tech’s Department of Biological Systems Engineering professor Percival Zhang.
• Dramatically cuts down on the size, shape, material and use of harmful chemicals (i.e. batter acids used to power devices.) • It is safer than traditional charging by reducing the risk of shock from an outlet.
• It would help reduce electricity demands on local utilities. • The nano filaments are made from a cheap, organic plastic called polyvinylidene fluoride. • The fibers are flexible and resistant to heat and chemicals as well as a dip in the wash. • They’re also small enough to blend unobtrusively into most garments.
• Much more environmentally responsible than traditional batteries considering it is bio-based. • No mining for ores necessary • Cheaper, reusable & biodegradable • Could potentially hold a longer more powerful charge than lithium ions.
• Could these garments have any altering affects on people with heart pacers or electric implants?
• Your traditional sweets and coffee may cost a little more.
• On a larger scale, what effects might these electromagnetic power waves have on our bodies and or other animals in the surrounding environment after prolong exposure?
Phase II Low volume Manufacturing Methods Ideation Vendor Selection Embroidery Process OEM Parts & Fasteners Bill of Materials Color Study & Selection
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Low Vol. Manufacturing Processes Phase II | Materials & Process
Compound Wood Bending Thin layers of wood are easy to bend into a variety of simple curves—that is, surfaces that bend in only one plane. The same approach can be used to create thin-walled panels that curve in two planes,for use as cabinet fronts, doors or sides, for drawer fronts, or for any other application requiring a compound-curved form. It is done by gluing layers of wood face to face into relatively narrow staves, making each stave take the shape of a different but related curve, and then joining the staves edge to edge. The key to the compound-staved lamination system is realizing that flat layers of wood can be bent to one radius at one edge, and to a different radius at the opposite edge.
Dough Molded Compound (DMC) Woodforce is a renewably sourced mechanical reinforcing material that can replace glass fiber for short fiber applications. A major advantage of the wood fiber dice over agricultural fibers is that they behave just like plastic pellets in the manufacturing process. This ease and accuracy of handling means the dice can be fed directly into conventional extruders, from which the compound can then go into injection molding as well as profile extrusion for processing as fiber-reinforced plastics. Wood fibers typically have lower costs and more consistent supply than other fibers, and wood-fiber reinforced plastics are stronger, lighter and have a lower environmental footprint than many plastics they would replace. Applications for this wood plastic reinforcement are wide-ranging and include automotive parts, household goods, furniture, extruded products and hardware components.
Direct Metal Laser Sintering (DMLS) The process involves use of a 3D CAD model whereby a .stl file is created and sent to the machine’s software. A technician works with this 3D model to properly orient the geometry for part building and adds supports structure as appropriate. Once this “build file” has been completed, it is “sliced” into the layer thickness the machine will build in and downloaded to the DMLS machine allowing the build to begin. The technology fuses metal powder into a solid part by melting it locally using the focused laser beam. Parts are built up additively layer by layer, typically using layers 20 micrometres thick.
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Material
Process
Why this process?
Finished Part
• The visual aesthetic follows the likes and home style of the persona. • Authentic and handcrafted piece. • Minimal tooling cost. • Minimal energy consumption.
• Low die costs (i.e. can use wood or modulan instead of steel.) • Low environmental impact. • Light weight to strength ratio. (cuts shipping cost.) • Controllable density.
• Injection molding would be impractical. • Zero tooling cost. • High quality part. • Can achieve very undular and thin wall shapes. • No secondary operations. • Numerous types of metals can be used for a robust part.
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Final Direction Phase II | Ideation
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Exploded View Phase II | Ideation
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Orthographics
Phase II | Orthos & Three point view R
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3
in
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3 in.
2.75 in. 37 in.
R 0.3 in.
R 0.5 in. R 4
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Three fourths top view.
Three fourths bottom view.
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Bent Wood Vendor’s Phase II | Vendor Selection Low Vol.
Company
Background
Why this Vendor?
Selected Vendor Selection 1
Sawyer Bentwood Inc. A family-run operation, Sawyer Bentwood has been in business since 1801, producing high quality hardwood products for over 200 years. Each piece is meticulously inspected and machined to our clients’ specifications. They work with companies who share our values and commitment to saving energy, increasing lumber yields and responsible, safe logging practices.
Selection 2
PureTimber Pure Timber produces bendable hardwood and bentwood products and fabrications using a proprietary Extreme Wood Bending™ process that produces the worlds most dramatic and ambitions bentwood fabrications from thick, solid hardwoods.
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• Uniformity, quality and consistency • 100,000 board foot kiln capacity • They welcome custom orders • Committed to preserving environment and resources • Made in the US • Ash, oak, cherry, maple and birch are some of the domestic hardwoods we bend.
• Can achieve extreme radi • They have had experience in speaker housing fabrication. • Uses minimal energy for fabrication. • Can form very thick woods.
General Information
Industry: Custom Bent wood manufacturing Founded: 1801, Whitingham, VT Headquarters: Whitingham, VT Products: furniture components, chair backs, musical instruments, canoes, kitchen cabinets, kitchen utensils, tool handles and more. Services: Rapid Bentwood Components. Custom Bending. Edge Bands. Table Skirts. Chair Backs and Bench Bow Backs. RockerRunners. Wood Slats. Wood Splats. Employees: 20 Certification: FSC Saw mills and resourcing
Industry: Custom Manufacturing Founded: 1989, Krailling, Germany Headquarters: Krailling, Germany with offices in France, Switzerland, Belgium, Italy, India, Nordic and Baltic, Singapore, Taiwan, UK and US Products: Musical instruments, furniture, architectural, interior design. Services: Cold wood bending, custom fabrication, custom parts Employees: +/- 100 Certification: N/A
DMLS & Injection Molding Vendor’s Phase II | Vendor Selection Low Vol.
Company
Background
Why this Vendor?
• Exceptional Lead Times • Low to High Volume • Proven Quality • Full-Service Manufacturing Solutions • U.S. Based Project Management • From Prototype to Production • Off-shore Pricing
Industry: Custom Manufacturing Founded: Valencia, California, U.S., 1991 Founder(s): Joe Allison Headquarters: Valencia, California, United Stateswith six other facilities located around the United States. Products: 3D Printed prototypes & parts, injection molded parts, cast urethanes, high quality plastics & metals Services: Rapid Prototyping, Direct Digital Manufacturing, Tooling & Injection Molding Employees: +400 Certification: ISO 9002
• Fast and flexible production of high-end parts. • Repeatable industry level of quality. • Freedom of design • Optimized part structures • Lattice structures as well as functional integration.
Industry: Custom Manufacturing Founded: 1989, Krailling, Germany Headquarters: in Krailling, Germany with offices in France, Switzerland, Belgium, Italy, India, Nordic and Baltic, Singapore, Taiwan, UK and US Products: Aerospace, automotive, industry, lifestyle, medical. Services: Rapid Prototyping, Injection Molding, Die casting Employees: +/- 400 Certification: ISO 9000
Selected Vendor Selection 1
Solid Concepts A custom manufacturing company engaged in engineering, manufacturing, production, and prototyping. Solid Concepts is an additive manufacturing service provider as well as a major manufacturer of business products, aerospace, unmanned systems, medical equipment and devices, foundry cast patterns, industrial equipment and design, and transportation parts.
Selection 2
EOS Manufacturing EOS is the technology and market leader for design-driven, integrated e-Manufacturing solutions for Additive Manufacturing (AM), an industrial 3D printing process. EOS offers a modular solution portfolio including systems, software, materials and material development as well as services (maintenance, training, specific application consulting and support). Customers profit from efficient manufacturing processes, optimized product quality and increased protection of investments. 20 years of experience in the Additive Manufacturing market.
General Information
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Embroidery Processes Low Vol. Phase II | Vendor Selection Low Vol.
Selections (4)
Technique & Process
Why this Process?
Abrasive Blasting
• No tooling costs, but masking may be required. • Low to high unit cost. • Very fine detains can be produced by skilled operators. • Rapid cycle time, but slowed down by masking, layering and carving
This is a generic term used to describe the process of surface removal by fine particles of sand, metal, plastic or other abrasive materials, which are blown at high pressure against the surface on the work piece and produce a finely textured finish.
CNC Engraving A precise method for engraving 2D and 3D surfaces, CNC engraving is a high quality and repeatable process. Filling engravings with different colors and the use of clear materials are effective ways to enhance design details.
• No tooling costs. • Moderate unite costs. • Very high quality • One-off to batch production. • Moderate speed spending on the size and complexity of engraving.
Hot Stamping A process in which an engraved image, hot stamping die or type, is heated then forced down against a part with a marking foil sandwiched in between. The area where the die meets the part, is where the ink from the foil is left behind
Laser Cutting/Etching A high precision CNC process that can be used to cut, etch, engrave and mark a variety of sheet materials including metal, plastic, wood, textiles, glass, ceramic and leather. This process burns away material leaving a charred look.
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• Tooling cost depends on stamp size and depth. • Can be used on a range of materials. It is a dry process, without mess. A very permanent process and very durable.
Selected Process • No tooling costs • Medium to high unit cost. • High quality finish, precision process. • One-offs to high vol. • Rapid cycle time.
I decided to choose this process because I wanted to give the logo a burned appearance. I feel this as a bit more natural and one off type of look. I picked this over Hot Stamping because this process uses less energy and can achieve much high quality.
OEM Parts & Fastening Phase II
Part
Size
Stainless Steel Cup Point Set
1/4” 94495A208
Price $1.23
Black-Coated Steel Pan Head Torx Machine Screws
3/8” 93701A304
$0.80
Stainless Steel Low Profile Socket Cap Screw
3/8” 93615A425
$1.17
Black-Oxide Alloy Steel Socket Head Cap Screw
2 in
$1.25
Tang Band W3-1053SC 3” Full Range Driver
Rubber Padded Adhesive Feet
91251A777
Why? A nylon locking patch on the threads ensures a secure grip. Screws are reusable and have a blunt tip that minimizes surface damage.
With more drive surface than Phillips and slotted screws, you can apply extra force without slipping. This allows for easy repairs if needed with out damaging the screw
For use where space is limited, these screws have heads that are a fraction of the height of standard socket head cap screws.
The standard among high-strength fasteners, these screws are stronger than Grade 8 steel screws.
3” 15 Watts Frequency Response $14.50 100 to 18,000 Hz Voice Coil Diameter0.875”
It has smooth, extended response, perfect for point source applications or line array. With a steel frame and neodymium motor and poly cone with rubber half-rolledge.
1/2 in
Low Profile design allows for the feet to be less obtrusive. There minimal height also lets the speaker sit lower to the surface on which it is sitting on to give it a more quiet look.
$1.25
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Bill Of Materials
Phase II | Tooling, Part & Material Cost Part & Tooling 1 10 100 500 1000 10000
Total investment per part
Top Bent Wood Housing Part 1 (Bent wood) (Compound Curvatue) Material & # of laminates 10-15 layers at $10 per laminate $100 Tooling (cold bent) Glue $10 300 300 30 3 0.6 0.3 0.03 Tool (cold bent) $250 Part (wood laminates) Machining Bosses & sanding (2nd Ops.) At $100 per Hr. Labor (2 Hrs) $200 100 100 100 100 100 100 100 Finishing (staining if needed) At $75 per Hr. Labor (1.25Hrs.) $100 $400 $135 $103.00 $100.60 $100.30 $100.03 Total $660 Enclosure Bent Wood Housing Part 2 (Compound Bent Wood) Tooling (cold bent) Material & # of laminates 10-15 layers at $10 per laminate $175 250 250 25 2.5 0.5 0.25 0.025 Glue $10 Part (wood laminates) Tool (Compound Mold) $300 175 175 175 175 175 175 175 Machining Bosses & sanding (2nd Ops.) At $100 per Hr. Labor (2 Hrs) $200 $425 $200 $177.50 $175.50 $175.25 $175.03 Finishing (staining if needed) At $75 per Hr. Labor (2 Hrs.) $150 Speaker Housing Total $835 Tooling (DMC) Part 3 DMC (Dough Molding Compound) 50000 50000 5000 500 100 50 5 Mold (Wood or Modulan) $200 Part (Speaker Housing + Mat.) Material (hemp) 2-4Ibs. $200 200 200 200 200 200 200 200 Manual Injection & 2nd Ops. At $100 per Hr. Labor $150 $50,200 $5,200 $700 $300 $250.00 $205.00 Total $550 Aluminum Speaker Screen Part 4 DMLS (Direct Laser Metal Sintering) Run Time + Labor Material (Metal) $200 2,400 2,400 2,400 2,400 2,400 2,400 2,400 Machining time At $200 per Hr. (12 Hrs.) $2,400 Part (Material) 500 500 500 500 500 500 500 Total $2,600 $3,100 $3,100 $3,100 $3,100 $3,100 $3,100 Felt Screen Run Time + Labor 20 20 20 20 20 20 Part (Die Cut Screen Backing) 15 15 15 15 15 15 15 $35 $35 $35 $35 $35 $35 TOTAL $54,160 $8,670 $4,116 $3,711 $3,660.55 $3,615.06 OEM Components Price Quantity Total Speakers 20 14 240 Circuit board 20 1 20 Wires 5 3 15 Cup Screws 1.23 8 9.84 Pan Screws 0.8 42 33.6 Cap Screw 1.17 7 8.19 Head Cap Screw 1.25 4 5 Rubber Feet 1.25 4 5 Total OEM cost 336.63 Final Cost per assembly 22 Taylor Lane
$4047.63
Part 5 Felt Screen Material (Felt) $15 Die Cutting Time & Labor $20 Total $35 SUM TOTAL $4,680
Color Study Phase II | Color Selection
Numerous hard and soft woods were experimented with. I decided that hard dark walnut was going to relate to my persona and his home environment more so than any of the other options. The aluminum screen cover will be coated in a medium to dark black natural color which will also reflect the dark and light contrast of he walnut wood grain. Each material is meant to bounce off of each other visually to give a unique aesthetic.
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CMF
Phase III Color Material & Finish | Vendor Selection Part
Bent Wood Housing (Top & Bottom)
Speaker Housing
Felt Screen Cover
Metal Screen cover
Color
• Black
• Earth Tone • Typically uncontrollable
• Black CMYK: 0,0,0,70
• Black CMYK: 0,0,0,70
Material
• Walnut • Linear grain
• Dough Molding Compound (DMC)
• Felt • Perforated
• Aluminum
Finish
Why?
• Sanded smooth • Natural stain (Semi-gloss)
The unique wood grain is admirable and gives it a sense of authenticity. The darker contrast evokes a sense of reliability and its ability to produce deep acoustics which resonate though the wood housing.
• Scattered mesh/fiber appearance.
DMC is a sustainable alternative to conventional injection molding. It uses a pulp based material and does not need immense pressure to be forced into the mold which also drives down tooling cost. It creates a strong and decently durable part with a unique aesthetic.
• N/A
This material was chosen because it gives an interesting transparency though the metal speaker screen while also protecting the inner piece of the housing.
• Gloss • Anodized (Natural)
This unique process called Direct Metal Laser Sintering (DMLS) is a 3D rapid prototyping method used for intersect forms. The complexity of the screen made it a perfect candidate for this process. An anodized black was chosen for a finish and more subtle appearance, while this dark color plays off of the dark wood grain.
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Fastening Methods Phase III | High Volume
Screen Fasteners These cup point screws will mount the screen to the rest of the housing. Pre-shaped holes will have been integrated into the 3D printed piece.
Speaker Fasteners These screws will mount the speaker cones to the Dough Molded Compound speaker housing, via pre-molded screw casings.
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Speaker Housing Screws These screws are held in place by the rear of the wood housing. They protrude enough to allow the speaker housing to be screwed into, keeping it in place and giving the speaker housing, the appearance as if it is floating.
Housing Fasteners Screws from the top will join the two bent wood housing pieces together. These screws are easily removable if the internal need to be reached.
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HDMI, auxiliary & inlet/outlet board.
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In Context
Phase II
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High Volume Design Problem Statement | Float Soundbar Design
The second half of this project was to create a high volume reiteration of the original low volume design. This high volume design posed many more constraints, regarding certain tooling methods, secondary operations and materials in order to keep the general costs down. This refined design language still aims at providing a unique aesthetic, but at a more reasonable cost to appeal to a wider audience scope.
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High Vol. Manufacturing Processes Phase I | Definitions, Applications & Processes
Material Injection Molding A manufacturing process for producing parts by injecting material into a mould. Injection moulding can be performed with a host of materials, including metals, glasses, elastomers, confections, and most commonly thermoplastic and thermosetting polymers. Material for the part is fed into a heated barrel, mixed, and forced into a mould cavity where it cools and hardens to the configuration of the cavity. Molds are typically constructed of metal, usually either steel or aluminum, and precision-machined to form the features of the desired part.
Wood Injection Molding (Woodforce) Woodforce is a renewably sourced mechanical reinforcing material that can replace glass fiber for short fiber applications. A major advantage of the wood fiber dice over agricultural fibers is that they behave just like plastic pellets in the manufacturing process. This ease and accuracy of handling means the dice can be fed directly into conventional extruders, from which the compound can then go into injection molding as well as profile extrusion for processing as fiber-reinforced plastics. Wood fibers typically have lower costs and more consistent supply than other fibers, and wood-fiber reinforced plastics are stronger, lighter and have a lower environmental footprint than many plastics they would replace. Applications for this wood plastic reinforcement are wide-ranging and include automotive parts, household goods, furniture, extruded products and hardware components.
Superforming A hot metal forming process that uses similar principles to thermoforming plastics, where a sheet of material is heated and forced onto a male or female superform using air pressure. There are 4 main types of superforming: cavity, bubble, back pressure, and diaphragm. The process is useful for producing complex surfaces.
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Process
Why this process?
Finished Part
• Allows for a more dynamic shape. • Cheaper material. • Relatively lightweight. • Durable.
• Lower material cost than injection molding • Low environmental impact. • Recyclable material. • Can use traditional Injection Molding machines. • Can still achieve dynamic shapes.
• Injection molding would be impractical. • Allows for a sophisticated part • Enables individual • Can use thin material such as Aluminum while still remaining a rigid part. • Perforated Aluminum allows for sound to flow though.
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Final Direction Phase I | Ideation
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Exploded View Phase I | Renderings
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Orthographics
Phase I | Orthos & Three point view
Rear View
R
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in
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3.25 in.
37 in.
2.15 in.
Front View
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Three fourths front view.
Three fourths rear view.
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Injection Molding Vendor’s Phase II | Vendor Selection High Vol.
Company
Company background
Why this Vendor?
General Information
• High quality, competitively priced, custom molded plastic components experienced staff, diverse molding capabilities and extensive secondary operation • Experienced manufacturer
Industry: Injection molding Founded: 1973, Gledora, Ca Headquarters: Glendora, Ca Products: aerospace to fitness and automotive to fast food dispensing Services: Specializes in custom molding of plastic and rubber parts. Employees: + 200 Certification: ISO 9001
• Builds molds in house. • Tooling products range from open and closed molds, multi sided, lift cores and complex parting lines. • Made in the US
Industry: Injection molding Founded: 1978 in Idaho Headquarters: Post Falls, Idaho Products: Musical instruments, furniture, architectural, interior design. Services: Cold wood bending, custom fabrication, custom parts Employees: +/- 400 Certification: ISO 9001
Selected Vendor Selection 1
SouthWest Plastics An industry leader for over 45 years, Southwest Plastics Company specializes in custom molding of plastic and rubber parts. Over the years they have evolved and changed with the industry while maintaining the traditional family values and work ethic. Using the latest technologies and techniques there reputation for precision molding quality service and value are well-known throughout the many industries they serve.
Selection 2
Heppner Molds They specialize in the manufacture of injection molds and injection molded plastic parts, and serve clients across the Northwest. Their manufacturing facility provides electronic, dental, consumer and industrial industries with quality plastic injection molding products and services. Heppner Molds builds all specifications of molds in-house — from prototype to multi-cavity, aluminum to heat treated tool-steel.
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Superforming Vendor Phase II | Vendor Selection High Vol.
Company
Company background
Why this Vendor?
General Information
• High Performance Lightweight Products into Specialist Markets • Manufacturing Excellence • Strong Technical Base • Forming up to 10ft x 6ft x 2ft • 5 Axis Cutting • Welding • Robot Hemming • Adhesive Assembly • CATIA CAE • CNC CMM Inspection
Industry: Superforming Founded: 1974, United Kingdom Headquarters: Worcester, MA with offices in UK, Europe, Asia, North America & Australia Products: Product Design, Automotive, Marine, Medical, Rail, Aerospace & Architecture Services: Bubble, Cavity, Diaphragm Back Pressure, Vacuum Furnace Employees: + 1000 Certification: ISO 14001-compliant
Selected Vendor Selection 1
Luxfer Superform Part of the Luxfer Group, Superform operates from two manufacturing facilities in Worcester (UK) and Riverside, California (USA). We specialist in Superforming Aluminium, Magnesium and Titanium components as a 1st Tier supplier to major OEM’s. With in house forming capacities enable large part manufacturing and complete solutions to customers.
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Embroidery Processes High Vol. Phase II | Vendor Selection Low Vol.
Selections (4)
Technique & Process
Why this Process?
Foil Blocking & Embossing
• Very low tooling costs. • High quality repeatable finish with fine edge detail. • Low volumes to mass production. • Different color of foils can be applied. • Very low environmental impacts.
This is a dry process used to apply decorative finishes to a range of substrates. A profiled metal tool is pressed onto the surface and leaves behind either a reverse image in foil or a relief pattern.
Pad Printing Pad printing, also known as tampo printing, is a wet printing process used to apply ink to a 3D and delicate surfaces. It can be used to apply logos, graphics and other solid color details to almost any material.
• Low tooling cost. • High quality and sharp edges, even on undulating surfaces. • Good approach for mass production.
Photo Etching This is surface removal by chemical cutting. It has a similar appearance to abrasive blasting. The surface of the metal is masked with a resist film and unprotected areas are chemically dissolved in a uniform manner.
Use Existing Tool By integrating the logo into the current superfomed tool the logo can be a part of the front screen. This approach requires no secondary operations to embroider the logo.
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• Low tooling cost. • Suitable for high volume. • Moderate to high unit cost. • This process does not affect the ductility, hardness or grain of the metal structure.
Selected Process • Uses current tooling. • Keeps cost down by engraving the logo in a tooling piece that is already being used. • The superforming process can achieve very high quality parts.
This process was chosen because it seemed the most logical because and did not require any secondary operations in order to get a logo. Due to superformings high quality parts, this detailed logo can still achieved. Superforming will also give the appearance of the logo being either raised or
Bill Of Materials Phase II | Materials & Process
Tooling & Part 1 10 100 1000 10000 100,000 Total investment per part Tooling Inject. Mold Housing Part 1 Spk. Enclosure 150,000 150,000 15,000 1500 150 15 1.5 Material (Plastic beads) $15 Material Price Tool (Aluminum Mold) $150,000 15 15 15 15 15 15 15 150,015 15,015 1515 165 30 16.5 Total $150,015 Tooling Inject. Mold Side Panels Part 2 Spk. Side Panels 20,000 20,000 2,000 200 20 2 0.2 Material (Plastic beads) $5 Material Price Tool (Aluminum Mold) $20,000 5 5 5 5 5 5 5 20,005 2,005 205 25 7 5.2 Total $20,005 Tooling Woodforce Part 3 Speaker Housing 50000 50000 5000 500 50 5 0.5 Material (Woodforce beads) $10 Part (Speaker Housing + Mat.) Tool (Aluminum Mold) At $100 per Hr. Labor $50,000 100 100 100 100 100 100 100 $50,100 $5,100 $600 $150.00 $105.00 $100.50 Total $50,010 Tooling Super Form Part 4 Spk. Screen 50,000 50,000 5,000 500 20 0.2 1.2 Mold (Steel) $50,000 Part Screen Material (Perforated Aluminum sheet) $50 50 50 50 50 50 50 50 $50,050 $5,050 $550.00 $70.00 $50.20 $51 Total $50,050 Total $270,170 $27,170 $2,870 $410.00 $192.20 $173 Sum Total $270,080 OEM Components Price Quantity Total Speakers 14.5 14 203 Circuit board 20 1 20 Wires 5 3 15 Cup Screws 1.23 8 9.84 Rubber Feet 1.25 4 5 Total OEM cost $279.22 Final Cost per assembly
$471.42
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OEM
Phase II | Color Selection Size
Part Alloy Steel Torx Drive Flat-Head Socket Cap Screw
Stainless Steel Pan Head Phillips Machine Screw
94414A112
3/8” 91772A066
$0.18
$0.12
Why? The Torx drive handles high torque and prevents your driver from slipping. Designed with a beveled neck and a flat head, these screws sit flush within countersunk holes.
They have a Class 3A thread fit, a minimum Rockwell hardness of C32, and a minimum tensile strength of 120,000 psi.
Tang Band W3-1053SC 3” Full Range Driver
3” 15 Watts Frequency Response $14.50 100 to 18,000 Hz Voice Coil Diameter0.875”
It has smooth, extended response, perfect for point source applications or line array. With a steel frame and neodymium motor and poly cone with rubber half-rolledge.
Rubber Padded Adhesive Feet
1/2 “
$1.25
Low Profile design allows for the feet to be less obtrusive. There minimal height also lets the speaker sit lower to the surface on which it is sitting on to give it a more quiet look.
$65
Lossless, uncompressed CD quality sound, Robust and dedicated 2.4 GHz audio network to reduce interference with cordless phones, microwaves, etc. Mac & PC, Long distance operating range
Outlaw Audio OAWA3 Amplifier
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1”
Price
3.26” x 1.45” x0.62”
Color Study
Phase II | Color Selection & Why?
A brief color study was done to compare and contrast some plausible directions for materials and finishes. Why? The reason I chose all black was that I felt that if subtly reflects its intricate details of the design. For example, the superformed front and rear screen is unnoticeable from a far, but as you get closer and look at the texture, you begin to appreciate the form language.
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CMF
Phase III Color Material & Finish | Vendor Selection Part
Color
Material
Finish
Why?
I chose black because I wanted it to match with the housing unit. More importantly, due to how intricate this screen is, I feel it would give it another visual element if this feature was discrete from a far, yet as you got closer to it, you are able to appreciate its complexity and pattern.
Speaker Screen Cover (Front & Rear)
• Black CMYK: 0,0,0,100
• 2024 Aluminum • Perforated 0.02 Inch Radius
• Anodized (Natural) • Polished High
Felt Screen (Front & Rear)
• Dark Grey CMYK: 0,5,5,90 • Perforated
• Felt • Perforated
• N/A
Felt Subwoffer Covers (Left & Right)
• Black CMYK: 0,0,0,70
• Felt • Perforated
• N/A
Main Housing (Side covers)
• Black (bold) CMYK: 0,0,0,100
• Plastic
• Gloss
The compound curvature of this piece as well as the heat staking required to bind this piece to the main housing was why I chose injection molding.
Power & Volume Switches
• Black (bold) CMYK: 0,0,0,100 • Lime Green CMYK: 60,0,90,70
• Plastic
• Gloss
The simplicity of the dial indicators easily communicate their function. Injection molding can easliy achieve certian desired molded impressions.
• Gloss
The complexity of this part which includes; ribs, snaps & bosses made Injection molding a perfect candidate. The simplicity of the aesthetic is also meant to more easily blend into its surrounding environment.
• Smooth
Woodforce is a sustainable alternative to traditionally injection molded plastics. It can still achieve the same fluidity in the molding process and does not require the injection molding machine to be retrofitted in any maner.
Main Housing Unit
• Black (bold) CMYK: 0,0,0,100
• Plastic
Speaker Housing
• N/A (Color is not controllable)
• Woodfocre (Sustainable Plastic Alternative.)
Screws (Speaker)
• Black CMYK: 0,0,0,100
• Machined Aluminum
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Fastening Methods Phase III | Injection Molding Fastening
Sonic Welding Ultrasonic welds will allow the side enclosures to be permanently adhered to the housing. This is done by melting the excess material on the piece, (see below) binding it with the housing unit. Because the shape is symmetrical, the same piece can be applied on both sides of the housing unit.
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Snaps located on the front and rear inner perimeter of the housing, the snaps will allow the front and rear aluminum screens to fit flush with the housing unit.
Bosses & Ribs The ribs add structural integrity to the housing and boss features. The bosses allow for the speaker housing to be stabilized in the housing unit, after it has been secured by several screws from the bottom.
Fastening Methods Phase III | Speaker & Housing Fasteners
Speaker Fasteners These screws will mount the speaker cones to the Woodforce speaker housing, via pre-molded screw casings.
Housing Fasteners Screws from the bottom will penetrate the boss features on the plastic housing unit and then be screwed into the speaker housing, keeping it secure in place.
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In Context Phase III
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