Advanced M anufacturing C hallenge By Nicholas Moore & Keon Johnson
Challenge In this project, we were tasked to design the mass production of bouncy balls. We had to cover 3 topics 1. The bouncy ball design 2. The injection mold design 3. The factory design
Bouncy ball design
Ask First we were tasked to make our own formula for a bouncy ball by using different materials and testing the mixing process
Imagine We did not know to make the balls so we decided to look for a recipe online and use the one we find.
Plan So after looking online we found the recipe that would be our control list. Materials on next page
1st Formula Description % 23.5 Elmer’s original glue 3.9 20 Mule team borax 23.5 Cornstarch 47.2 Distilled Water 1.9 Food coloring
Initial Process 1. pour 3 teaspoons of glue into a cup 2. mix it with 3 teaspoons of cornstarch 3. In another cup dissolve 1 teaspoon of borax into 6 teaspoons of water. 4. By ¼ of a teaspoon, gradually add the borax solution to the 5. Roll the ball until it’s done.
Create We used this process for our first experiment. This did not go well because the ball won't bounce So we changed the amount of borax, and cornstarch to make the ball harder.
Improve By using the results of the experiment, we were able to make a recipe that would make a ball that was hard enough to bounce. Our final product was able to bounce up to one brick on Mr. Wolfe’s wall. Materials on next page
Final Formula Description % 22.64 Elmer’s original glue 7.55 20 Mule team borax 22.64 Cornstarch 45.28 Distilled Water 1.89 Food coloring
Final Process 1. pour 3 teaspoons of glue into a cup 2. mix it with 3 teaspoons of cornstarch 3. In another cup dissolve 1 teaspoon of borax into 6 teaspoons of water. 4. Pour the glue-cornstarch mixture into the borax-water solution and mix 5. Roll the ball until it’s done.
Injection mold design
Ask Now that we have made the formula we had to make a mold that would make the balls This design had to include the injection of the rubber and the ejection of the balls when they where done
Imagine At first we had the Idea of a revolving mold that would make the balls at a very fast pace But, we realized that this wouldn't work because there would be no way to cool it
Plan We came up the idea of having multiple molds filled at a time. We then planned to have pipes of cool water to cool down the mold. Finally, the mold would be pushed out by pegs and sent to quality control
Create The we started to sketch out the mold to see what it would look like. Sketches on next slide
Improve After seeing how the sketches turned out, we decide to make a 3d model of the mold so we could see all parts of it Videos on next slide
Factory
Ask After by making the injection mold, we had to make the factory including: raw materials station, process, mixing station, injection mold center, quality control, and shipping.
Imagine To gain some ideas on how to design the factory, we looked online. We mostly looked at tire factories because they also have to work with rubber.
Plan Our plan was to have a conveyor belt to bring the raw materials to the mixing station The mixing station would be a banbury mixer which was a mixer design to mix rubber Then the rubber would be sent to the injection mold station to make the balls The balls will then be inspected by cameras and will be operated by an employee Finally the inspected balls would be shipped to toy stores
Create After making the plan for the factory we started to make some sketches to see how it would turn out. Sketches on next slide
Improve After making the map of the factory and the sketches, we started to make the 3D version of them. This allowed us to see how the factory would look in real life. We also decided to not change the design of the injection mold center from the one we made before Videos on next slide
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