Contents

419 Assignment - Engineering Design........................................................................................................... 2

Introduction: ................................................................................................................................................. 2
Objectives: .................................................................................................................................................... 2
Location used: ............................................................................................................................................... 2
Task: .............................................................................................................................................................. 2
Scope: ............................................................................................................................................................ 2
Customer Requirements and design parameters and design limitations, .................................................... 3
1.1 Analyse possible design solutions ........................................................................................................... 4
1.2 Evaluate Conceptual Designs .................................................................................................................. 5
1.3 Justify the selected design solution ........................................................................................................ 6
1.4 Assess compliance of design solution ..................................................................................................... 6
2.1 Key features of computer software in the design for the manufacturing process ................................. 7
Selection of Software .................................................................................................................................. 10
2.3 Available computer software that can assist the design process, ........................................................ 11
3.1 Advantages and Disadvantages of Product Standardisation ................................................................. 12
3.2 Elements involved in the total cost of manufacture ............................................................................. 13
3.3 Manufacturing processes and material requirements for components ............................................... 14
4.1 Researched customer requirements including design parameters. ..................................................... 17
4.2 Used design information from appropriate sources to prepare the design specifications,.................. 18
2.2 Used computer software to produce design drawings or schemes. ..................................................... 18
4.3 Assessed customer requirements against design limitations ............................................................... 19

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419 Assignment - Engineering Design

Introduction:
Design and manufacturing process for a bottle cap pressing machine for a reputed
water bottling plant in the Seychelles. The assessor will pose and serve as the customer.
Several meetings with the customer were arranged to identify the customer's
requirements as well as the initial design concepts. Further meetings were arranged to
discuss the final design and go through production procedures and compliance.

Objectives:
To design a cheap, lightweight, and durable accessory or tool to fix the bottle cap manually without
much effort once the bottles are filled. This toom must quicken the process.

Location used:
Seychelles

Task:
The Sodepak filtered water bottling plant has requested us to provide a simple solution to fixing bottle
caps to their 20 and 12-litre water bottles. The plant averages filling approximately 6000 bottles per day
for local demand. The automated machine keeps breaking down and the investment for a new machine
cannot be justified.

Scope:
The following areas will be covered in this assignment,

The Task: Identify the potential design task criteria and parameters required by the customer. To ascertain
the requirements, several meetings were carried out with the customer and myself. The objective is to
offer a solution that is based on the essential and desirable parameters of the customer and exceeds his
requirements and expectations.
Concept-level solutions: Offered a choice of 4 concept-level designs to the customer after the initial
meetings. Each concept has been suggested with its strengths and weaknesses so that the customer can
have a better idea of the suggestions. The objective is to offer the customer a variety of choices so that he
can make an informed decision on the final design.
Selecting the final design: The customer and I agreed on the final proposed design together after
evaluating the concepts and weighing their strengths and weaknesses. The objective is to select the most
suitable proposed design in line with the customer's requirements and expectations.
Final Design Concept: The final design concept will be presented to the customer (assessor and his
nominated group) This will be in line with the requirements of the customer. The objective is to offer the
final design concept complying with the customer's requirements and its compliance or non-compliance
with all design limitations.
Manufacturing the design: The method used for the manufacturing of the design is explained in this part
together with the software used with the merits and weaknesses of each. This is to identify which software
is best suited to design the product.

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Compliance of final design: Here we need to assess the final proposed design to ensure it complies with
the customer's requirements. The objective is to ensure that all specifications given by the client have
been met.

Customer Requirements and design parameters and design limitations,

Low cost: The suggested concepts must be low-cost to manufacture and this is an important requirement
for the customer. Costs can be reduced by using materials that are cheap and easily available and using
manufacturing methods. Need to consider a low-volume manufacturing method with different types of
processes and techniques to manufacture a small number of parts. Other ways to reduce costs would be
lean manufacturing with reduced waste and reselling or reusing waste material and opting for
manufacturing methods such as injection moulding or similar.

Durability: The suggested concept tool needs to be durable and long-lasting with less wear and tear due
to frequent use. This largely depends on material selection, strength, corrosion resistance, recycleability
and biodegradability. It should be manufactured with materials that are long-lasting and high quality.
Materials such as Aluminium or stainless steel which are resistant to corrosion or polymers such as ABS,
High-Density Polyetheylene (HDPE) or Polycarbonate that are durable, tough and workable. Durability
tests under realistic or simulated test conditions need to be carried out to check durability. Welding is a
source of durability failure in most cases. So should be used only if necessary

Lightweight: The suggested tool needs to be lightweight, easy to handle and portable. Materials such as
Aluminum or Thermoplastic materials such as Polypropylene (PP), ABS or HDPE would be ideal. Since it is
operated by hand, the weight needs to be minimal making it convenient to handle. Also can consider
hollowing out centres or excess material to reduce weight. Further, creating honeycombed sections can
reduce the weight but still maintain its structural strength.

Strength: The suggested tool must be strong enough to resist the impact created by punching the cap to
the bottle and cannot break, chip or be deformed. It must not lose its form by its continuous operation.
The tool can be supported by adding ribs or moving a hole from a high-stress region to a low-stress region
to increase strength and reduce failure. Avoid sharp corners in the design and add features such as fillets
to increase strength.

Aesthetic: Requires a design that is pleasing to the eye. Materials such as Aluminium, stainless steel and
HDPE may give a pleasing finish since they are easy to work with.

Design limitations,

Deadline: the customer is under a limited time constraint requiring the project to be completed in 1 week.
This is on a tight time limit considering that approval has to be sought from governmental entities. An
important factor is that no manufacturing can be carried out on Sundays due to confined space.

Resources: Considerations to be given when selecting the tools and the processes due to limited
availability of same. Special consideration should placed when selecting the correct and cheap material
for the tool. Some materials may be difficult to find locally due to the nature of the country and will need
to be imported.

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1.1 Analyse possible design solutions

Concept 1: The bottle cap press-down machine. Recommend the cap pressing machine
which has a lever to press the cap on. The machine has a base on which the bottle can
be placed and the cap can be pressed onto the bottle using the lever. This is a simple
piece of equipment. The cap can be plugged into the cap holder and pressed down to
the bottle.

Advantages: Can be placed within the production line where once the bottle is filled, the cap can be
pressed manually by the staff. It can be assembled at the end of the refill line or floor level in a different
location. Can be used for both types of bottles (12 & 20 litres). Extremely easy to operate by 1 staff
member, It is lightweight with movable parts depending on the type of material used. No stress on the
staff as the pressure is applied by pulling the lever down.

Disadvantages: Production time may be longer due to the various parts and assemblies involved.
Production cost may be of concern due to the additional parts and materials used. May take longer to
complete the task due to the load, punch cap, and unloading process. This will result in limited caps being
fitted. Safety issues due to moving parts. Less durable due to the moving parts and may be Bulky to handle.

Concept 2: The cap presser - Staff can easily press the lid onto the bottle. The cap
can be plugged into the cap holder and pressed down to the bottle.

Advantages: Convenient and easy to use and move around with. A staff member
can walk around the filled bottles pressing the lids onto the bottles which saves
time and has the flexibility of fixing a large number of caps to bottles in one go (in
batches). Convenient long handle to press. Used on both types of bottles. Can use body weight to press
the cap. It is lightweight and easier to produce.

Disadvantages: Physical force has to be applied by the staff member. Not suitable for members with wrist
issues or back problems. May break the cap or damage the bottle if excessive force is used.

Concept 3: Weighted impact cap presser. The weight on top can be

pulled back due to the spring-like tension on the handle and released.
The force created by the moving weight will punch the bottle cap into
place upon impact.

Advantages: Convenient and easy to use and move around with. No

physical force is required by the staff member as the force is created by
the weight. Saves time and has the flexibility of fixing a large number of
caps to bottles in one go. Convenient long handle and spring-like
tension to create pushing force. Used on both types of bottles. Less bulky than the other concepts. Possible
injury due to high-velocity moving parts.

Disadvantages: May produce unwanted sound by the two contact points banging against each other. May
break the bottle cap if excessive force is used or cause injury to fingers or other parts.

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 Concept 4: The cap-pressing mallet

Advantages: Lightweight and extremely easy to operate. The staff need to tap the cap
onto the bottle using minimal force. No massive force is needed as the cap can be
tapped into place with one tap using the wrist. The soft material face will not damage
the bottle cap which may crack if excessive force is used. The faster operation means
more bottles can be supplied daily and the possibility of increasing capacity due to
flexibility of use.

Disadvantages: Continuous hammering may cause discomfort to the wrist. Need to

hammer accurately else the bottle cap may break

1.2 Evaluate Conceptual Designs

The following is a summary of the merits and weaknesses of the 4 concepts

Concept 1 Concept 2 Concept 3 Concept 4

Strengths Can be Placed at the end of
the new or refill line which
allows for convenient
installation of bottle caps.
Ease of use due to
convenient moving parts.
Can be operated by 1
person.
Weaknesses Higher manufacturing costs
due to many parts and
materials.
Safety issues such as
pinching due to moving
parts.
Easy to use.
The cap can be plugged in
with one press movement.
Lightweight
Portable
Many caps can be fitted in
a single round
No moving parts
Durable and strong
Difficult to operate on the
refill line as the bottle
needs to be on floor level.
Cannot be operated by
staff who have back
problems.
Lightweight
Portable
Many caps can be fitted in a
single round
Durable and strong
Uses several materials
Makes an annoying noise on
the impact of weight.
Injury due to parts moving at
high speed
Easy to operate.
Fix the cap in 1 simple move
of tapping
Portable
lightweight material
absorbs any impact.
Can be used to cap many
bottles in 1 go (batches),
either on the new or refill
line or on the floor.
No prior knowledge is
needed to operate
Cheaper to manufacture
Accurate hammering is
required

Less durability due to
moving parts
The slower rate of caps
pressed due to the loading
and unloading of the bottle.
Bulky to handle and move
around.
Possibility of cap breaking
due to excessive force
applied.
Less durability due to impact
Takes time to fix caps as
pulling movement is required
for each bottle
Require experienced staff to
operate.

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1.3 Justify the selected design solution
The following weighted matrix will help you to determine which Concept is best suited for the
requirement.

Criteria Weight Concept 1 Concept 2 Concept 3 Concept 4

Score Total Score Total Score Total Score Total
Low Cost 5 2 10 4 20 2 10 5 25
Durability 4 3 12 5 20 2 08 5 20
Lightweight 3 2 06 4 12 3 09 5 15
Strength 2 2 04 3 06 2 04 4 08
Aesthetic 1 3 03 4 04 3 03 4 04
Total 35 62 34 72

5 – High 1 - Low

As you can see from the above matrix, concept 4, which is the cap-pressing mallet is the most versatile out
of all recommended concepts and this has been accepted and confirmed by the client.

1.4 Assess compliance of design solution

Health and safety requirements,
The Seychelles government stipulates that people with disabilities or ailments refrain from operating
machines or equipment which can worsen their condition. Therefore, we have recommended our
concepts using the most simplistic and practical method with minimal force requirement for operation.

The recommended materials to manufacture are aluminium, or aluminium mixed thermoplastic polymer
material ABS, or ABS and Polypropylene. Each material has its health and safety measures.

Aluminium is inert and non-reactive when used correctly and potential health and safety impacts are
limited to the customer. Therefore, the Aluminium grades used must be standardised and proven to be
safe for manufacturing the cap-pressing mallet. To maintain proper health and safety regulations,
Aluminium should be purchased from producers who are certified following the ISO 9001 quality
standards.

No lead or mercury should be mixed with the aluminium. Also, Aluminium work involves using chemicals
that can harm a worker’s health. Welding fumes, metal dust and chemical solvents are potential chemical
hazards to staff members. Therefore, any member who is working with Aluminium fabrication needs to
wear the proper PPE attire and work in a well-ventilated area.

Acrylonitrile Butadiene Styrene or ABS used in manufacturing is safe and non-toxic to the end user. The
substance does not degrade over time nor will it release any dangerous compounds or chemicals over
time.
ABS is not considered or listed as a hazardous material under the Hazardous Substance category of the
Seychelles Environment Protection Act of 2016 (Supplement to the Official Gazette of 5 September
2016).

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It’s important to highlight that ABS plastic carries risks during any “melting process” as the terpolymer
breaks down into individual polymers like acrylonitrile and styrene. This risk extends to the application of
solvents on components from 3D-printed patterns for smoothing purposes.
Moreover, ABS plastic poses environmental hazards. A significant concern is the release of ABS dust and
tiny particles into the atmosphere during 3D printing, a known health risk. These particles can irritate the
skin, eyes, and lungs.

However, when handling ABS during manufacture, Staff must wear gloves including necessary PPE clothing
and breathing apparatus as the ABS sheet or film will contain residual amounts of Acrylonitrile (AN)
monomer, a suspected human carcinogen.

ABS film or sheet will burn when exposed to an external source of ignition. The gases, fumes and particular
matter evolved from a burning ABS substance are toxic. The expected major hazards from burning ABS
are intense heat and very high levels of dense, black smoke containing Carbon Monoxide and Hydrogen
Cyanide which are very harmful to humans.

End-of-life disposal,
All materials used for the concepts can be recycled at the end of their product life with no or minimal
impact on the environment.

Due to its corrosion resistance, Aluminium can be recycled repeatedly needing only a fraction (5%) of the
energy required to produce it initially. Also, no impurities contaminate the Aluminium during recycling.
This makes Aluminium an excellent material to manufacture the mallet. At the end of life, the tool can be
recycled without deteriorating the quality of the metal and requiring very little energy to do so. This is an
energy saving of 95%. The post-consumer aluminium scrap can be melted and turned into something new.
The most CO2-efficient recycled aluminium products are the ones made from post-consumer scrap.
Recycling of Aluminium helps protect the environment and boost sustainability.

Without endangering the consumer's health, ABS is built to last with repeated use.
ABS is entirely recyclable as well. The plastic can be melted down and remoulded to create a new part at
the end of a product lifecycle. This reduces production costs and promotes environmental protection.
The energy needed to recycle ABS is significantly lower than the energy required to produce ABS from
virgin materials. Recycling ABS reduces waste and prevents pollution by diverting waste from landfills
and incinerators.

2.1 Key features of computer software in the design for the

manufacturing process
Merits and weaknesses of using computer software for the design and manufacture of cap press mallet,
Computer-aided design or CAD software plays a major role in designing a product for manufacture. Unlike
in the past when paper and pencil were used to create 2-dimensional sketches for a product, Computer-
aided design software is widely used to create 2D (2 2-dimensional) sketches and drawings. These 2D
sketches can be converted to 3D parametric models using the same software for 3D (3-dimensional)

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printing or CNC machining in manufacturing. The CAD software offers tools for developing, altering,
visualising in a virtual setting, and manufacturing the necessary Cap presser.

Some of the advantages and disadvantages of Computer software are as follows,

The software saves time taken to draw sketches for the cap pressing mallet which relates to increased
productivity. A Simple part takes only seconds to draw which saves time. This time saved can be used to
draw other parts or improve the mallet product which is an increase in productivity. Parts on 1 design can
also be used in other designs reducing total time spent on the project.

2D sketches for the mallet are easy to edit when done using computer software which automatically
changes the corrections made on the 3D parametric model. Improve in accuracy, Manual 2D sketches may
have human errors, whereas computer software will eliminate almost all the errors due to controls and
restrictions. Shapes and surfaces are complex for a human to draw and can be drawn easily using computer
software.

Clearer drawings make fewer errors hence better quality and accurate final products are produced. It
further reduces errors with features such as joint simulation, and interference checking which results in a
final product with much fewer errors. It allows different components to be virtually assembled and
simulations carried out to check if they are functioning as intended by the designer. The simulations will
avoid errors and save on costly rework during manufacture.

Better quality components (mallet) are produced due to the added functions which give the user more
options to create aesthetically pleasing models. It is easier to understand and comprehend complicated
2D drawings with the use of its 3D model. The 3D model can be viewed on all planes (sides) to better
understand the final product. It is also a convenient tool to explain the product to someone with less
understanding or without an engineering background.

Another advantage is that the software allows material and weight optimisation. With the help of weight
optimisation, the designer can come up with a cap-pressing mallet design that is lightweight which helps
with keeping the manufacturing cost down. By simulating mallets' structural performances, designers can
reduce material from regions where it is not required without compromising on strength or durability.

3D modelling and visualising the mallet from different angles or planes making it easier to comprehend
and make necessary adjustments to the design or check if it is aesthetically pleasing. The software also
enables the designer to make changes, improvements or modifications to the mallet or experiment with
different concepts to check which concept suits the best.

Precise measurements and geometry can be used to design components for the cap presser with accuracy
resulting in an accurate final design which is convenient when manufacturing.

Since all files are digital, people need not carry bulky drawings and many people can work on different
parts of the same product in different locations creating quick and easy collaboration.

Computer software can be used to create a mould for injection moulding, fed into a 3D printer or a CNC
machine which makes the manufacturing process faster thus reducing the requirement for additional
manpower.

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Computer software can be incorporated with an ERP system (Enterprise resource planning) which reduces
the time on areas such as Material requirement Planning (MRP) or Bill of materials (BoM).

On a negative note, skilled operators are required to operate the software. Skilled operators may be scarce
and a substantial amount of time and money may be spent in training the in-house staff.

This kind of software can cost a substantial amount of money to purchase which some companies may
not be able to afford.

Further, breakdown or virus attacks on computers may cause data to be lost which could result in redoing
projects all over again costing time and money. The software also needs to be updated and upgraded
regularly.

Applications of Software in design for manufacture process CAD & CAM

Computer software is used in mainly 2 areas where one area is the design stage which is known as
computer-aided design (CAD) and the other area is computer-aided manufacturing (CAM)

CAD is the use of computer-based software which can help an engineer or designer in their design process.
CAD is the solution to digitally creating a 2D drawing and its corresponding 3D model of real-world
products before they are manufactured. With CAD software designers can share, review, simulate and
modify designs easily creating a pathway to fresh and original thinking and contrasting products which can
reach the consumers much faster than the previous manual system of paper/pencil sketches with trial-
and-error production.
CAD software can enhance and organise a designer’s workflow resulting in efficiency, time saved increasing
overall productivity thus providing a better-quality product to the consumer.

While CAD is used for designing and drafting the product, CAM or computer-aided manufacturing is used
for the manufacturing aspect. The engineering design created through CAD is converted into machine
language and fed into CNC (computer numerical control) machines or 3D printers for production. The
codes are read by the machine which instructs various tools to do the machining. This process is called
computer-aided manufacturing (CAM). CAM importantly reduces Costs, wastage, Lead time and errors
while enhancing accuracy, surface finish, consistency, and manufacturing speed.

Applications of using computer software in design for manufacturing process,

Boeing: As a leader in the aircraft industry, Boeing relies heavily on CAD software to design, and simulate
aircraft components and systems. The software plays a crucial role in ensuring the safety and efficiency of
the aircraft. The CAD software also helps aerospace engineers to do complex calculations quickly and
accurately.

Automated systems increased the possibility of merging designs and aerospace engineering services into
a single process which resulted in cost-saving benefits and time efficiency. Aerodynamics, passenger
capacity, power, and fuel efficiency can be tested on simulation with accurate results using finite element
analysis services.

Engineers use CAD software to build a 3-dimensional model based on vehicle data sets. This is known as
drafting and the purpose is to create a virtual representation of what the aircraft will be.

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Boeing uses 3D parametric modelling to draw the aircraft parts and sub-systems. Parametric modelling
does not just draw the parts to resemble their physical shapes but gives them real-world behaviours. Apart
from the parts’ dimensions, the data set includes weight, material characteristics, and tensile strength.
Both surface and solid modelling techniques are utilized to give the parts their attributes.

Additive manufacturing, much like CAD, has proven to be a significant player in the development of flight
vehicles in the aerospace industry.

Boeing uses 3D printing to prototype intricate parts. Additive manufacturing can only create objects from
plastic materials, so the prototype is not likely functional. The printed object enables manufacturing
companies to examine intricate details and dimensions accurately. 3D printed parts are mock-ups
manufactured without using various specialized tooling.

General Electric: GE uses CAD software in its manufacturing processes to design and optimise complex
machinery such as turbines and medical equipment. This enhances their production and efficiency.

They use additive manufacturing to manufacture most parts since it allows the production of lighter, more
durable, and more efficient designs. Additive manufacturing uses CAD software and 3D object scanners to
direct hardware to deposit material layer by layer in precise geometric shapes.

Selection of Software
We selected Fusion 360 as the software to design the selected concept no 4 which is based on our
meetings and your subsequent feedback. The following features make it the most suitable,

Strong and effective 2D and 3D modelling possibility,

Fusion 360 can perform detailed and effective 2D and 3D designs which enables the designers to create
an accurate and detailed model of the mallet tool. The excellent features offered by Fusion 360, make it
possible to create precise and accurate geometry, use parametric modelling to visualise the model and
create changes to the design to improve the quality of the component or product.

Flexibility and Compatibility,

Fusion 360 is versatile and compatible with other programmes and file formats allowing it to support a
wide range of complex design applications and industries. This results in streamlined processes from
designing to manufacturing including easier and more collaborative communication with suppliers and
service providers. It produces a bill of material (BOM) with a click of a button.

Clearer manufacturing drawings,

Fusion 360 provides accurate engineering drawings which are easy to read and understand by the
suppliers, other manufacturers, or shop floor staff. The drawings offer accurate dimensions,
specifications, notes, and instructions to the shop floor staff to manufacture the mallet tool with
precision.

Integrated CAD CAM Environment,

One of the key features of Fusion 360 is the CAD/CAM environment. When the design is complete and
you need to make a prototype or the actual 3D model, it can be done in one tool: Additive, subtractive
manufacturing as well as injection moulding. This eliminates the need to share files and streamlines the
whole process from design to manufacture.

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2.3 Available computer software that can assist the design process,
Merits and weaknesses of different available software packages in the design for manufacture process,

CATIA - is a 3D product modelling and design tool used across multiple industries.
CATIA is an excellent and effective tool to create complex geometries and large assemblies. The best
feature of this tool is its surfacing capability. Ideal for various types of design and modelling software like
solid surface and sheet modelling. It has a good export option when you want to analyse parts using
different software. Further, it has in-built modification management abilities, saves time and money,
reduces the effect of changes in the manufacturing process, No need to restart the whole process from
the beginning. Assists in managing multi-part geometries including core-stiffened parts. In-depth
productibility checking predicts the behaviour of composites and makes necessary changes.

The disadvantages of CATIA are that it is a less user-friendly interface compared to other software, and
has some difficulty in product modelling, complex mouse operations, and complex software programming
resulting in a long waiting time to load files to make changes. Also has difficulty in updating an existing
design.

Solid Edge - Solid Edge is a software solution for product development — 3D design, simulation,
manufacturing, data management, and cloud collaboration. Solid Edge aims to combine the speed and
simplicity of direct modelling with the flexibility and control of parametric design.

Advantages include excellent sheet metal and assembly designs and great simulations. It has a generative
design toolbox which accelerates the design process and frees the designer to perform more advanced
design functions. It is compatible with other CAD designs making it very user-friendly.
One of the best advantages of Solid Edge is the richness of details it provides, which allows for a higher
level of precision in design work. The software also offers a larger number of features, which can be very
helpful in creating complex designs. Analysis of design can be done using 2D drawing. Also offers great
customer support. Cheaper in price compared to some other software. Also has a student version which
is completely free to use for students

The disadvantages of Solid Edge are that the software crashes regularly, and Finite Element Analysis (FEA)
or stress simulation cannot be done in this software. Another downside of Solid Edge is that the learning
curve is steep. Since the software has so many features, it can be difficult to use at first.

SolidWorks – Solid modelling computer-aided design, computer-aided engineering, 3D CAD design and
collaboration, analysis, and product data management software.

The advantages are that it is a great software to use for 2D & 3D designing, and is very user-friendly with
many features. It is a very powerful software for mechanical design. It has good FEA and is versatile in
performing basic analysis of components and validating designs. It can produce BOMs which is an
advantage for manufacturing. Further advantages include ease of integration with other software, has a
good user community where expertise can be shared or exchanged resulting in issues being resolved
quickly.

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Disadvantages include needing a lot of RAM on your system, which can drain the battery life of your laptop
due to actual life-like graphics. Sometimes you may need an additional graphics card. An important
negative to note is that the error messages are vague and do not indicate the specific details of errors.
Other disadvantages include spontaneous system crashes from time to time without recovery, and many
features which make it confusing and difficult to understand to new users. Compared with other software,
it is relatively expensive.

Fusion 360 – is a platform for 3D CAD, modelling, manufacturing, industrial design, electronics, and
mechanical engineering.

The advantages are that it is available at a variety of prices ranging from large-scale corporations, small-
scale manufacturing businesses, start-ups, hobbyists, and students. Since it is a cloud-integrated software,
other co-designers and stakeholders can work on the same project simultaneously in different locations.
Offers integrate and real-life simulation allowing users to accurately test their designs. Inbuilt powerful
tools allow real life-like rendering. Other advantages include Designing and 3D modelling, Importing, and
exporting file types, Data management and collaboration, manufacturing (CAM/CNC machining),
Electronics, Simulation, In-product chat, and technical support for finding solutions to any designing
problems faced and grants access to Fusion 360 extensions and generative design.

Disadvantages – Software is prone to frequent crashing and sometimes takes time to load. The keyboard
controls cannot be customised as required by the user. Unannounced feature updates frequently which
may confuse and irritate the user. Unlike other software, Fusion 360 needs a high-speed internet
connection and users could lose data or files due to lost internet connection.

3.1 Advantages and Disadvantages of Product Standardisation

Product standardisation is to ensure that the mallet tool upholds certain standards for product quality and
appearance in whatever market they are available in. Standardisation ensures that customers all over the
world receive the exact product no matter where they purchase it from. A standardised product will use
the same raw materials, same manufacturing processes, same branding, and packaging even though they
may be manufactured in different locations.

Advantages,
Lower production cost – With efficient manufacturing processes, wastage of material, and labour is
minimised resulting in profitability which can be passed on to the customer. When every member is
working the same way, it is easier to see bottlenecks or waste of resources and resolve these issues
immediately.
Strong brand reputation – Consumers are aware and guaranteed what they will receive when it is a
standardised product. This creates loyal customers creating a higher market share.
Greater clarity and predictability - Standardisation minimises errors since the processes are known or
predictable, they can be planned more easily avoiding unnecessary surprises.
Knowledge retention – By standardising processes and tasks, it is easier to document them. The knowledge
is retained even if an important staff member leaves or is sick.
Greater flexibility – Staff rotations become easier since all the processes are standardised and staff are
aware of what they need to do in case of a rotation. If products and tools are standardised, it reduces the
time needed to find replacements.
Consistent quality – Since the inputs do not vary every time, the outputs too will not vary giving quality
products consistently.

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Easier compliance - Each manufacturer needs to comply with a national or international set of standards.
Hence standardisation acts as a control mechanism in place to help companies comply with all the rules,
regulations, and requirements.

Disadvantages –
Inefficiency – By applying uniform standards to different projects it can become inefficient due to each
project having its unique requirements.
Control on innovation – Standardised processes may discourage creativity and innovation as people are
focused on the process.
Competitor issues – In a market, if competitors are providing personalised products or experiences,
maintaining a standardised product or service will be a disadvantage.
Fewer choices – When products are standardised, variations become limited giving fewer choices to
consumers.

The product standardisation used for this product is based on local regulations of the Seychelles Standard
Bureau – Manual for packaged drinking water. We are using the local regulations for manufacturing as well
as the standard local cap size of 55mm.

The following weighted matrix of design parameters will assist in determining which Concept is best suited
for local regulations.

Criteria Weight Concept 1 Concept 2 Concept 3 Concept 4

Score Total Score Total Score Total Score Total
Standardisation of 5 5 25 5 25 5 25 5 25
product
Manufacturing 4 2 8 3 12 4 16 5 20
process
Size 3 2 6 3 9 3 9 3 9
Weight 2 2 4 3 6 4 8 4 8
Health and Safety 1 5 5 5 5 3 3 4 4
Total 48 57 61 68

5 – High 1 - Low

3.2 Elements involved in the total cost of manufacture

Elements involving costs in manufacture,
The following key areas of costs need to be noted when manufacturing the cap presser tool,
• Direct material cost
• Direct labour cost
• Manufacturing overheads cost or indirect costs

Direct material Cost – this is the cost of materials used to manufacture the product requested by you.
Direct material costs include raw materials and or parts that go into manufacturing the assembly. This will
include material costs, shipping and clearing costs, transport costs and any other expenses that are
incurred to bring the materials to the warehouse.

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The following steps will help,

• Ascertain the standard quantity of the material used to manufacture one unit.
• Add the standard amount of scrap associated with manufacturing one unit.
• Determine the standard amount of scrap associated with setting up the production run, and
apportion it to the individual unit.
• If any scrap is sold, apportion the revenue back to the individual unit.

For many materials, the cost of scrap and the revenue from the resale of scrap are so small that it is
not worthwhile to apportion it to the material cost.

Direct labour costs – This includes salaries and overtime paid to the staff who are directly involved
in manufacturing your part. In other words, this is the amount of payroll expenses paid to direct
labourers who are involved in manufacturing the bottle cap presser tool. To calculate direct labour
costs, We need to track the time spent on each activity to manufacture your product. This will be
completed on a time sheet.

Manufacturing overhead costs- overhead costs include direct factory-related costs that are incurred
when producing your product, such as the cost to operate the machinery, rent and utilities of the factory.
Other costs that will be included in the overhead costs are indirect material costs and indirect labour costs
as explained below.

Indirect material costs items such as disposable safety equipment, glue, air hose etc...
Indirect labour costs are wages, benefits and insurance paid to the security personnel who patrol the
premises at night.

There may be other costs in terms of obtaining Patents, compliance fees, testing and development
and market research and marketing for your product if you do intend to sell this product locally or
overseas.

3.3 Manufacturing processes and material requirements for components

The following 2 manufacturing methods are feasible based on the design parameters given by the
customer.

Injection Moulding: Injection moulding has no fixed costs for every application and will differ on factors
such as type of product or component, and its size. However, I give the applicable cost impact below,

1. Moulding tool cost – It is an expensive process to machine the mould and the mould base for the
cap-pressing mallet tool. It is a one-time asset for which the customer must bear the cost. At the
end of the manufacturing process, this mould may be kept with the customer for future use.
there are several ways to machine the mould,

CNC machining – is well suited for making moulds out of Aluminium or Steel material. It will
remove excess material with precision from a block to machine the mould inside. Skilled labour
is needed to operate the CNC machine. This process is great if you intend to re-use the mould
later.

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 3D Printing – This is much faster and ideally suited for making moulds for plastic injection
moulding products. The mould may be printed using 10K resin. This does not require a skilled
operator. However, the mould may experience shrinkage over time.

2. Equipment cost- Electric moulding machines use an electro servo motor which directs the machine
during injection moulding. These machines use minimal energy and incur low operating and
maintenance costs. Even though of the high initial investment costs, these will not be passed on
to the customer. The cost applicable for equipment will be based on the machining time.

3. Plastic resin and additive costs- A kilo of plastic resin ABS or PP, will range from US$ 2.00 to US$
2.60 per Kilo including shipping, clearing and transport. The material weight of the cap presser
tool is 300 grams. Material wastage is approximately 4% by weight.

4. Labour and other costs – The following labour costs will be applicable based on the man/hours
calculated to manufacture the product.

Setup cost – Machine set-up and configuration for each stage of the injector moulding process.
Operator cost – Even though the process is automated, operators need to monitor the
Processes and the finishing and appearance of the final product.

Low-volume plastic moulding is the manufacturing of a few parts ranging from 100 onwards Generally
we make the moulds in-house and perform the moulding ourselves without using sophisticated
machines. The complete manufacturing run for low-volume moulding is approximately 5 days to create
and finish the cap presser tools.

3D Printing: It is easier with 3D printing to print a prototype for testing before we print the whole batch.
The following cost impacts apply,

1. Material cost – is the most important cost of the 3D printing process and will depend on the type
of printer used.

Filament-based printer – Uses ABS or PLA filaments as the material. This printing process is
relatively cheap and the materials are commonly available in the Seychelles. 1 KG of ABS
filament is US$ 20.00 and wastage is approximately 2% by weight. 1 KG of metal-filled filament
with Aluminium powder will cost approximately US$ 40.00 per kilo.

2. Equipment and maintenance costs – Commercial 3D printers are expensive and need routine
maintenance, calibration, and replacement of parts for them to work in perfect order.
Equipment costs will be based on the machine times.

3. Labour costs – Labour costs are significantly reduced for 3D printing since manual labour and
machine setting up or configuration time are eliminated. This cost will also include labour costs
for finishing and appearance where excess material will need to be trimmed off.

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 Proposed materials for manufacturing

ABS (Acrylonitrile Butadiene Styrene):

ABS is a widely used thermoplastic that is highly regarded for its durability, affordability, and strength.
Due to its excellent dimensional stability and flexibility, it is possible to create the bottle cap pressing tool
using ABS. ABS offers an excellent combination of properties and is reasonably priced and easy to use
with 3D printing or injection moulding.

Polypropylene
PP is a versatile thermoplastic that is widely known for its strength, flexibility, and affordability. This
material offers superior impact strength, dimensional stability, and chemical resistance. It has excellent
mechanical qualities and is lightweight, making it a popular choice for various applications.

Aluminium mixed ABS

Given below is a summary of the processes and cost impact of above above-mentioned manufacturing
processes and materials

Injection moulding - Injection moulding - 3D printing - ABS 3D printing -

ABS PP Aluminium/ABS
Volume 100 100 100 100
Method In-house mould outsourced mould In-house 3D printing In-house 3D printing
production and in- production and in-
house moulding house moulding
Mould 3D printed polymer CNC machined - -
Aluminium
Lead time 5days 5days 1 weeks 1 weeks
Equipment required 3D printer & injection 3D printer & injection 3D printer 3D printer
moulding machine moulding machine
Mould cost US$ 100.00 800.00 --- ---
Material cost US$ 2.00*100*1.04*0.3 2.60*100*1.04*0.3 20.00*100*1.02*0.3 40.00*100*1.02*0.3
= 62.40 = 81.12 = 612.00 = 1224.00
Labour cost US$ 250.00 200.00 150.00 150.00
Equipment cost US$ 5*8*5 = 200.00 5*8*4.5 = 180.00 2*8*7 = 112.00 2*8*7 = 112.00
Total manufacturing cost 612.40 1261.12 874 1486.00
Cost per unit US$ 6.13 12.62 8.74 14.86

Our recommendation: is to manufacture the cap punching mallet using ABS as the material and to use
in-house injector moulding as the manufacturing process.

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4.1 Researched customer requirements including design parameters.
The mallets available in the market are similar in design. However, they cannot be used to fix bottle caps
due to the following,

Cost: The cheapest price of a mallet is US$ 36.76 including the

shipping cost Therefore it is cheaper to manufacture this specially
tailor-made bottle cap mallet as per the given price.

Weight: The mallets for sale are heavier with a net weight of 450
grams. This weight is known to be too heavy for constant use. A heavy
blow from this type of mallet will damage the bottle caps resulting in additional expenses. . The tool
designed is ideally weighted at 300 grams which is easy to use.

Durability: The imported mallet is not guaranteed against breakage and will start chipping and separating
as time goes by. This is mainly due to the reason that it is a mixture of fibreglass and rubber which is not
a durable material.

Health and safety: the Seychelles government has no restrictions on the importation of plastic, rubber or
fibreglass goods (except styrofoam) provided that the importer has the necessary license to operate a
business and an importation permit issued by the Ministry of Finance. However, the goods imported
should not include any toxic chemicals or asbestos as banned under the Stockholm Convention. The toxic
chemicals prohibited are HCB, PCB and DDT.

Other design alternates,

An alternate design solution available in the market is this machine
operated via a foot peddle. This is run on alternating current. The price of a
unit is approximately USD 600.00 excluding shipping and import tax. Using
this machine will result in higher electricity bills (commercial rates) Even
though this machine is easy to use it is dangerous to be used in water-
bottling plants due to electrical leaks/ health and safety issues. It must be
assembled in a separate area

Another solution is this similar design machine with adjustable height. The
cost is USD 360.00 excluding shipping and tax. This is heavier than the
recommended design as it is made with Stainless steel. This has rubber studs
at the bottom which makes this design anti-slip and ideally suited for bottling
plants. However, with the limited height, it cannot bottle 20-litre bottles.

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4.2 Used design information from appropriate sources to prepare the
design specifications,

The design is based on consultation and recommendations with the following persons,

Designer: To reduce weight, use a honeycomb structure inside the mallet head which gives it the precise
weight and force.

Stress Engineer: It was recommended to manufacture the mallet as one unit instead of manufacturing
the head and handle separately. This will eliminate the stress on the joint and prevent the mallet head
from separating from the handle when in use.

Patent team: The design must be in line with the Seychelles Standards Bureau (SBS) guidelines for
manufacturing goods. An application must be lodged for the approval of the design. Once approved, the
product will carry the SBS mark and this is a certification of quality assurance to the customer.

THE FINAL PRODUCT PRESENTATION

Based on your agreement and requirement of 100 units of cap punching mallet (Concept 4) we
recommend that that the most cost-effective method to produce would be the use of the injection
moulding process using ABS material. This is cheap, lightweight, durable, and readily available in
Seychelles.

2.2 Used computer software to produce design drawings or schemes.

The final design overview,

General view front view side view

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4.3 Assessed customer requirements against design limitations
The manufacturing process,

The design: The first step in the manufacturing process of the mallet is to prepare the final design using
CAD software.

3D print the Mould: Based on the dimensions of the CAD model of the mallet, a mould is 3D printed
using resin. The shape of the mallet is formed by the core and cavity sections of the mould when molten
plastic is injected into to mould. Note must be taken on the following,
• The gate length of the mould should be less than 1mm
• Vent width should be set between 4 and 6mm.
• The thickness should be set between 0.025 – 0.05mm.
• The channel diameter should be 3mm

Material Selection: Based on the customer confirmation, Acrylonitrile Butadiene Styrene (ABS) is
selected. Based on the weight and wastage of the material, the quantity needed is 32 kilos.

Treating ABS: ABS readily absorbs moisture. Therefore, it needs to be treated in an oven to remove
moisture. If not treated, the finished product will become cloudy, and bubbles or other surface defects
may appear.

Pellet Melting: The ABS plastic pellets are fed into the injection moulding machine reservoir; They will
then be heated to 230° C to a molten state at the required consistency. Melting the ABS to this
temperature will ensure that the finished product has a gloss finish.

Injection: The molten plastic is pumped into the mould cavity under intense pressure at 50 MPa or 500
Bar. High injection pressure is required due to the viscosity of the material. Once the mould is sealed,
the plastic fills the cavity and takes the shape or form of the cap-pressing mallet. At 50MPa pressure,
friction and sticking of moulded parts are reduced
.
Cooling and Solidification: To shape and solidify the molten plastic, the mould is cooled down through
the use of cooling fans, air jets and water channels built into the mould. To ensure that the plastic
solidifies properly, the cooling duration and temperatures must be carefully managed and controlled.

Mould Opening and removal of mallet: Once hardened, the mould can be opened and the mallet can be
released using air ejection or ejector sleeves. Multiple mallets can be produced if we use a mould with
several chambers

Finishing: Excess plastic material also known as flash (wastage at the edges), needs to be de-flashed
once the tool is removed from the mould. The methods we use to do de-flashing are trimming, tumbling
and precision grinding. This would give the mallet tool the finished look as in the design.

Quality Control: To ensure that the mallet is manufactured to the correct standard, quality checks must
be carried out. This can be in the form of a visual inspection to ensure that the mallet is up to the
standard required by the customer. Any mallets that do not pass quality inspections can be recycled to
create another product.

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 Final design compliance
Deadline: We discussed the requirement of obtaining approval to manufacture the cap-pressing mallet
with the Seychelles Standards Bureau. We explained the constraints and managed to expedite the
matter to obtain the approval in 2 working days. All required documentation including our business
licence and manufacturing licence were presented to expedite the matter. While the required approvals
were sought, the required resources such as materials and tools were prepared to start manufacturing
immediately once approval was given. To overcome work on Sunday, we had to arrange for the labourers
to work overtime during the other manufacturing days. This made the process faster and the required
quota of 100 units was given to the client on time.

Final Cost,

Injection moulding - ABS

Volume 100
Method In-house mould production and in-house moulding
Mould 3D printed polymer
Lead time 5days
Equipment required 3D printer & injection moulding machine
Mould cost US$ 100.00
Material cost US$ 2.00*100*1.04*0.3
= 62.40
Labour cost US$ 250.00
Equipment cost US$ 5*8*5 = 200.00
Total manufacturing cost 612.40
Cost per unit US$ 6.13
Mark up per unit 35% US$ 2.1455
Selling price per unit US$ 8.30

The Engineering drawing is attached herewith.

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