modelxdesign

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Plastic Product design and Mold design services

Model X design is specialised in all type of Plastic Product design and Mold design services in London and Around. Below is one the case study of Design & development of Baby wipe container.

Problem Statement:

● The wet wipes need to be accumulated inside the product, so the design should ensure that the product has to be airtight

● The existing concept design has an issue with wall thickness & the part is complicated to revise the design

●  An issue with finding a suitable suction cup (Off the shelf) that has to be mounted over the wall with the product & also should make sure that there is no damage occur on the suction cup while traveling

● Diaper clip & Lanyard Strap needs to be added to the product for more feasibility

● Due to the requirement of high volumes of component, there is a proposal for Injection mold design

Solutions Recommended:

● User experience & Aesthetics of the product is optimized based on the requirements

● Market research was carried out to find out the best suction cup availability as per international & manufacturing standards

● Reduced the no. of suction cups by following the proper calculation methods chosen the standard specifications for the manufacturers

● Redesigned the wipe container with the suction cup by adding the sliding attachment

● The suction cup is press-fitted inside the base plate & a sliding mechanism was implemented in the design which helps to remove the container from the base plate which is fitted on the wall, this helps the user to wash the entire part & refill the wipes easily

● The design was optimized in such a way that keeping the base part upside down so that no damage will occur on the suction cup while traveling

● Mold/Tool design was created from conceptual to manufacturing design using Progressive mold components & PCS mold base

● Proper material selected for the product & Tooling based on the properties & functionality requirements

Conclusion:

● The design process is followed by a parametric method using the SolidWorks software

● 3d modeling, Detailed tool drawings, BOM are completed and manufacturing standards are reviewed and verified

● The completed mold is inspected against a comprehensive checklist

● Optimized design improves the user cases & better serviceability

● DFMA & DFMEA methods were helped to reduce the assembly time & cost, and also ease of manufacturing

● The mold/tool is designed is taken care of in such a way that the product has to be created with a high-quality & manufacturability, that is simple and efficient, long-lasting, easy to operate and maintain, and that meets all required specifications at the lowest possible cost

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Product design & Design for manufacturing (DFM) services

Model X design is specialised in all type of Product design & Design for manufacturing (DFM) services in London and Around. Below is one the case study of Design &Development of Mobile wipe case

Problem Statement:

● The wet wipes have to be accumulated inside the plastic case, so the product has to be airtight

● Given input of product design was not followed the proper design process & manufacturing techniques

● The existing product has an issue with the wall thickness & the part is complicated to revise the design

● The input Cad model was not a parametric model to make future changes/updates

● Due to the requirement of high volumes & accurate component, there is a requirement for Injection mold design

Solutions Recommended:

● The mobile case was designed as per the wipe specifications to meet the requirements

● Adjusted the inside volume/compartment to make overall wall thickness to 1.2 mm & keeping overall outside dimensions as per the requirement

● HDPE material was chosen as per the applications & requirements

● Solidworks 3d parametric model was created using reverse Engineering process (from the provided STEP file)

● Functionality check is done by providing proper tolerance/Fitments & DFMA applications

● Mold/Tool design was created from conceptual to manufacturing design using standard components & LKM base

Conclusion:

● The general wall thickness of the part was maintained at 1.2 mm for better product stability

● Compact design for aesthetic looks & better user cases

● The objective of designing the cost-effective mold/tool for a specific component was achieved by DFM methods

● Product files delivered with the 3d models, 2d manufacturing drawings with Bill of materials & relevant documentations

● The design validation was done using DFM & mold flow analysis to demonstrate the design is safe and stable

● By referring to the product drawings & specifications, mold critical dimensions were controlled in the design to ensure the product accuracy & also this helps the future modifications/changes much easier.

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Mechanical engineering design & development in London

Model X design is specialised in all type of Mechanical engineering design & development in London and Around. Below is one the case study of Design and Analysis of piercing tool with Special Purpose Hydraulic press

Problem Statement:

● The sheet metal component has to be produced in cup shape along with holes at high accuracy levels

● The limitation in this operation is any metal cutting operations such as trimming, piercing etc has to be carried out as secondary operation in order to maintain geometry relation. As the deep drawing operation is carried out in plastic deformation stage any holes previously pierced in sheet metal before drawing will get affected

● Due to requirement of high volumes of component there is proposal for piercing tool with special purpose hydraulic press

● Component pdf drawings were available as an input& the requirement was 3d cad (Computer-Aided Design) modelling &2d detailing services.

Solutions Recommended:

●  All the drawings were produced using Solid works

● Using a stage tool for piercing as a secondary operation holes produced in deep drawn component for maintaining the accuracy

● The hydraulic press designed and analyzed to ensure high stiffness, low cost and compact. The hydraulic circuit is designed, simulated and functionally verified using Automation tool

● Piercing tool is designed based on calculations. By arriving the overall bounding dimension of the press frame, the shape optimization was conducted to design the structure with minimal mass

Conclusion:

● The objective of designing the cost effective piercing tool with hydraulic press for specific component was prepared

● The design validation using virtual FEM software demonstrate the design is safe and cost effective

● Careful selection of materials resulted in reduced the overall cost of manufacture and increase in durability

● Mass production of component is more effective with the usage of hydraulic press/special purpose machine.

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Engineering design services

Model X design is specialised in all type of Engineering design services in London and Around. Below is one the case study of Agricultural machinery – crop harvesting

Problem Statement:

● Due to the gradual increase in population, there is too much of demands in the Agricultural sector to increase supply of crops

● Lack of human resource in rural areas

● Manual operation resulted in minimal production

● Heavy machines cannot be implemented due to affordability and limited area of cultivation, innovations in finger millet has been stand still for a long period of time

● Existing drawing were in paper format & the requirement was Mechanical 2d to 3d cad convertion & manufacturing drawings.

Solutions Recommended:

● Drawings were converted into vector format (CAD format) and drawing standard to    ISO(using CAD Conversion and Migration Services)

● Needed design optimization/modification for existing machines to make it more efficient and reliable based on client standards/requirements

● It is very essential to bring a portable machine which is cost effective, compact and easy to use

● 3D parts, assembly design and manufacturing drawings with bill of materials were created using CAD Design and Development Services

● The kinematic analysis is carried out using Simulation through which the motion of the blades in the cutting mechanism is verified. The forces acting on the bearing due to the rotation of the rollers are found and the bearings are selected based on the result obtained

Conclusion:

 ● This machine helps in increasing productivity

● Great time saving

● High precision components are designed for the manufacturing process by applying GD&T design approach using our Engineering Design services

● Cost effective and ease to use machine.

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3D modelling and 2D mechanical drafting services

Model X design is specialised in all type of 3D modelling and 2D mechanical drafting services in London and Around. Below is one the case study of Heavy engineering equipment.

Problem Statement:

● Input was 3D scanned IGES model

● Old data was not available such as 3D parametric models and manufacturing drawings

● The client needed to create 3D parametric model with design optimization then simulate and strengthen the backhoe-loader concerning with stress under maximum loading condition and different boundary conditions.

Solutions Recommended:

● Finite element analysis (FEA) is the most powerful technique in the strength calculations of the structures working under known loads and boundary conditions. Analysis outline the critical points of the design early and design improvisation can be done before producing prototypes

● With respect to analyses results, the backhoe-loader arms need an improvement to increase its strength

● FEA simulation is performed and 3d parametric model created using our mechanical design & analysis services.According to the analysis result, the backhoe-loader is strengthened with the use of reinforcements.

 Conclusion:

● Reverse engineering services (RE)done by our engineers helped to decrease the repetitive work for future requirements

● Theoretical calculations were matched with FEA simulation results

● Strength of the backhoe has been increased by approximately 10%