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My personal favorite project!
Have you ever tried to remove a staple cleanly in one piece, only for it to snap, bend, or make you fight with it? In my Design for Manufacturing (DFM) course, I took that simple frustration and redesigned the traditional staple remover with user experience, manufacturability, and cost in mind. I applied product development principles such as DFM/DFA, FEMA, FEA, and GD&T to figure out not only how to make the product easier to use, but also how to manufacture and assemble it as efficiently and affordably as possible. This project gave me a much better understanding of what actually goes into bringing a new product from an idea to something that can realistically be manufactured and used.
100 : 1 Scale
Decision Matrix
Design for Experiment
DOE was use to find the most robust design and optimal pivotal point force. I then used Monte Carlo simulations to model real-world manufacturing variation and see how tolerances could affect the final product.
I performed tolerance analysis to make sure the individual parts could realistically fit and function together once manufactured. Instead of assuming every part would come out perfectly, I accounted for real-world production variation, dimensional tolerances, and worst-case conditions.
Validation with FEA
Future works: Creating tooling to cut and stamping sheet metal , taking to suppliers for materials and manufacturing methods, and surveying the public’s opinion about the new product from a technology-push perspective.
Top Skills Utilized
DFM/DFA
MathLab
FEA
Product Design
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