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Mobile Phone Holder
Design for Manufacture
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Mobile Phone Holder Project
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IntroductionVariety of Processes and
Manufacturing Techniques
Production of Artifacts
Enhance Problem Soving and Design Capabilities
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IntroductionPress Forming using ‘Foamex’
Solutions to Real Life Design Situations
Development of Individualised Products
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Introduction
•Thematic Approach
•Encourage Integration of Topics
•Adapt Projects to meet individual Circumstances
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Objectives
•A Range of Manufacturing Skills:- Heat forming
- The use of jigs and formers
- Marking out, cutting, drilling, finishing and assembly of materials.
•An Understanding of The Characteristics of Thermoplastics Materials
Students will Develop:
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Objectives
•Graphics/Design skills and techniques
•Product Analysis Techniques and Design Specifications
•Ability to Design according to User Requirements
•Research Skills using ICT
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PresentationTheme:
Mobile phones are a worldwide phenomenon that have revolutionised the way we communicate with one another. They are both desirable and essential to our everyday lives.
The ways in which we carry, protect and secure our mobile phones can be based on fashion, practicality and function.
Design Brief:
Design and make a functional mobile phone holder suitable for personal or desktop use
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Constraints•Work within student skills range
•Manufacturing Processes:
- Press forming
- Vacuum Forming
•Functionality and Ease of Use
•High Standard of Finish – Use of Graphics
•Individualised Product
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Research/Investigation•Designers need stimulation
•Provision of stimulation
•Personal Research – How did it influence the thought process
•See accompanying presentation on Research – Add to it
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ResourcesMaterials•3mm expanded foam sheet (Foamex)
•1.5mm Vacuum forming plastic
•18mm MDF or suitable material for production of moulds and formers
•Grip range press fit nylon click fasteners
•Tie wraps
•Acrylic cement or solvent
Equipment•Oven
•Vacuum former
•A range of hole saws or forstner bits
•Scroll saw
•Wet and dry paper
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Making the Formers
•Male and Female Formers – 18mm MDF
•Simple Shapes
•Female – Larger by thickness of casing material•Male – Fixed to Base (Allignment)
•Taper – Not necessary, Radius top edge
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Heating and FormingMaterial is placed in pre-heated oven(See Temperature chart )Heated material is draped over male former
Locate female former over male former
Force together and hold until material cools
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Cutting
Material can be trimmed to leave a 10mm lip
File and finish to shape with wet and dry paper
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Cut casing material in half using a scroll saw and file to finish
Support bracket can be marked from casing but
its profile is cut 5mm smaller all round and
filed to finish
Support Bracket
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Casing is affixed to support bracket using tensol
solvent/cement or a glue gun
Assembly may need to be supported with masking tape during the gluing process
Assembly
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Bending
Support Bracket can be bent using a Strip Heater
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Finished Project
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Design VariationsA number of design variations are
possible using this process
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Extension Concepts
•Survival Kit•Swimming Holidays•Jewellery•Power Pod•CD Storage•Camping•Pamper Pod•Baby Gear•Handsets/Remote Control•Pencil Case
•Personal Alarm•Mouse House•IT accessories•Desk Tidy•Radio Housing•Instrument Case•Toolbox•Robot Shell•Money Box•Paintbox Store
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Material Oven Temp. °C
Time(Seconds
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Notes
3mm Foamex
140 30 If plastic becomes mishapen, it can be returned to the oven and reheated.
3mm Plastazote
140 60
6mm Plastazote
140 90
Times & Temperatures
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LinksTEP International Manufacturing Centre
University of Warwick
Coventry CV4 7AL www.tep.org.uk
www.crclarke.com
Middlesex University
Teaching Resources
Unit 10, IO Centre
Waltham Cross
Herts EN9 1AS www.mutr.co.uk
Click Here to view instructional video