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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