Design for Manufacturing
Design for Manufacturing is a senior level course at Olin college, consisting of major hands-on projects designed to allow students to familiarize themselves with DFM principles through self-guided learning. Students are allowed full creative control over the content of their projects, so long as the required processes are utilized and profitability calculated. All CNC machining, thermoforming, 3D printing, urethane casting, and injection molding was done by the student creating the project, giving us a meaningful knowledge base for the manufacturing process.
Injection Molded Ring
This project utilized injection molding and urethane casting to create a piece of gachapon-style costume jewelry. A custom injection mold was designed and manufactured via CNC mill, and masters of the insignia plates were SLA printed at a layer height of 0.025 mm. A mold was made of the insignias, and cast with chrome-tinted urethane.
Including the cost of design, investments in machining and molds, materials, and the assembly time as priced by industry standards, each ring (assuming a batch size of 120000 units) would cost $0.28 to make, with a projected profitable sell price of $0.78, well within an acceptable range for a gachapon toy.
Lava Bucket Nightlight
This project explored the use of thermoforming and 3D printing in the manufacturing process through the creation of a nightlight. The "Lava Bucket Nightlight" is inspired by the popular computer game Minecraft, marketable to the demographic of young children and video game enthusiasts. The outer shell was FDM printed and finished to appear stainless steel, and the lava insert was vacuum-formed on a printed ABS buck and airbrushed with a "lava" gradient.
The unit has a simple, robust construction with minimal parts and an elementary fabrication process, lending well to both surviving the rigorous wear and tear expected of a child’s commodity and the potential scaling of production given sufficient demonstrated demand.
Macro-Key Box
This project explored the use of CNC milling and the design of registration features in the manufacturing process through the creation of an electronics enclosure. The "Macro-Key Box" was designed for backstage lightboard operators, with a slim enough profile to remain fairly ergonomic while prevents misplacement in low-light conditions. The box was milled from 6061 aluminum using a Tormach 770, with the top and bottom pieces powder coated in baby blue and clear finishes respectively. The box housed an Adafruit QT Pi RP2040 capable of keyboard emulation, as well as two Adafruit Rugged Metal Pushbuttons to serve as the switches for the hotkeys.
Sunshine Bay Residence
Equipped with full air conditioning, a private pool, 3 on-suite bedrooms, and a spacious open living room kitchen area, Sunshine Bay Residences is an excellent choice for anyone dreaming of their own safe haven.
Bridgewater Joy Residence
Co-designed by the world-renowned architect James Smith, our Bridgewater Joy residences offer top views of the nearby lake Michigan. Perfect for a small family, a professional couple, or anyone looking to set up a home office.
Pleasantview Gem Inn
Not just pleasant on the outside, our Pleasantview Gem Inn properties are especially popular among families. With underground parking and floor-to-ceiling windows, there's no shortage of natural light or space.
