1. RPI Storage Box with Removable Dividers Kaleigh Iler: Columbia HS & Nabihah Azhari: Troy HS

2. Product Design

4. Product Strengths Allows for easy organization of small items Allows for easy organization of small items RPI logo facilitates school spirit RPI logo facilitates school spirit Flexibility in design Flexibility in design Requires multiple MILL processes Requires multiple MILL processes Can be manufactured within budget Can be manufactured within budget

5. MILL Processes Plastic Injection Molding Plastic Injection Molding Abrasive Water Jet Cutting Abrasive Water Jet Cutting CNC Machining CNC Machining Powder Coating Powder Coating Ultrasonic Welding Ultrasonic Welding Vacuum Forming Vacuum Forming Laser Cutting Laser Cutting Robotic Assembly Robotic Assembly

6. Sides Two identical parts CNC machined mold Plastic injection molded Fit together at corners Sides 6” long together

7. Aluminum Bottom Cut by abrasive water jet cutting Powder coated for finish 1/8” thick

8. Side Assembly Ultrasonic welding Fits around aluminum bottom to secure Bottom View Top View

9. Corner Pieces CNC Machined Fits around corner Powder coated for finish Secured with purchased screws [Grainger Industrial Supply] Screw hole 1/16” diameter

10. Dividers Plastic injection molded CNC machined mold 2 Large dividers 5 Small dividers Large dividers made in two equal pieces and ultrasonic welded together

11. Divider Layout

12. Lid CNC machined mold Plastic injection molded Made in 4 pieces and ultrasonic weld them together Indented circle in top for logo 3/16” Thick Indented 1/16” 3 ¼” Sides 3/4” Overlap

13. RPI Logo Raised RPI Logo vacuum formed Cut out by laser cutting Attached using ultrasonic welding inside indented circle Logo raised ½” above lid surface

14. Side View

15. Processes Summary Plastic Injection Molding: Creates sides, dividers, and lid Plastic Injection Molding: Creates sides, dividers, and lid Abrasive Water Jet Cutting: Creates aluminum base Abrasive Water Jet Cutting: Creates aluminum base CNC Machining: Creates plastic injection molds & aluminum corners CNC Machining: Creates plastic injection molds & aluminum corners Powder Coating: Colors aluminum base & corners Powder Coating: Colors aluminum base & corners Ultrasonic Welding: Attaches sides, dividers, & lid Ultrasonic Welding: Attaches sides, dividers, & lid Vacuum Forming: Creates RPI logo for lid Vacuum Forming: Creates RPI logo for lid Laser Cutting: Cuts out vacuum formed pieces Laser Cutting: Cuts out vacuum formed pieces

16. Alternative Ideas Product could be made as a “Do It Yourself” project, with minor design changes Product could be made as a “Do It Yourself” project, with minor design changes –Technical writing skills Different divider arrangements Different divider arrangements

17. Cost Estimate Material General Cost Cost per Box Total Cost (400) Large Mold $500/mold$1.25 $500 (1) Small Molds $250/mold$1.25 $500 (2) ABSDonatedDonated$0 Vacuum Form Plastic DonatedDonated$0 Aluminum$5.00/lb$0.50$200 Screws$16.00/100 $1.28 (8) $512 Powder Coating $5.00/lb$0.88$350 Total-----$5.16$2,064

18. Any Questions?