1:30 pm – 6:30 pm:
TH15-Product Design and Development
(Moderators: Pavan Valavala and Mohan Shanmugan)-Room S320D

1:30 pm – 2:00 pm:
Modeling Doming Deflection of Caps and Closures With Finite Element Method

Wenbo Xu, Dow Chemical
As part of an effort to develop light weight closures for carbonated soft drinks (CSD), a finite element model has been developed to understand the impact of resin properties and closure design on the end product performance. Phase I of the model development is to understand the deformation mechanics as a precursor to light-weighting effort. The model simulates typical loading conditions in CSD closures and predicts the resultant stress & strain in the closure. The current study focuses on the doming deflection of CSD closures. Preliminary results are in excellent agreement with the experimental results. The FEA results and experimental data suggest that viscoelasticity of the resin i.e. high density polyethylene (HDPE) plays an important role in determining the long term performance of CSD closures. The current report introduces the key techniques applied in the model development and summarizes the results of the model and the validation experiments.

2:00 pm – 2:30 pm:
Quasi-static, Non-linear, Explicit Finite Element Analysis of Small Pet Bottles

Naser Imran Hossain, Niagara Bottling
Packaging design must be a forethought when producing ecofriendly packaging in the water bottling industry. Bottle design research is often restricted by mold production delays and long lead time on physical prototyping. A simulation based approach, or virtual prototyping can create an effective bridge between concept and production phases of the process with a relatively short lead time. This study explores a Quasi-Static Finite Element Approach with non-linear approximations to model water packaging. The study also shows how top-load is used as a metric of structural performance for small PET bottles. The material parameters are based on Polyethylene Terephthalate (PET), the material of choice in the bottling industry.

2:30 pm – 3:00 pm:
Design for Manufacturability – 3D-CAD Design Methodology for Spiral Milled Polymer Processing Tools

Phil Hungenberg, Universität Duisburg-Essen
3D-CAD systems show limitations with regard to the design process of helical milled parts. This paper introduces a surface based design methodology, which enables the designer to bypass these restrictions. Additionally, an approach to facilitate an early knowledge transfer between production planning and design department is shown and implemented through the use of knowledge based engineering methods. Thereby a virtual product model is generated that represents the exact work piece geometry and contains specific manufacturing information while meeting the functional requirements of spiral mandrel dies and thus impacting the whole process chain positively. Furthermore, a method to optimize certain sections of the flow channel which show subpar flow properties is introduced.

3:00 pm – 3:30 pm:
Knowledge-based Product Planning and Designing of Injection-molded Parts

Rene Andrae, University of Duisburg-Essen
This paper presents a procedure for an integrated design process regarding injection-molded parts. The support of the designer occurs from a knowledge-based production process and material selection, throughout the designing to a rheological part optimization. Techniques of the model-based systems engineering (MBSE) were used for the acquisition of requirements as well as for the development of this supporting system. For validation, selected methods are implemented and tested in a CAD-system.

3:30 pm – 4:00 pm:
Influence of Thermal Treatment on the Mechanical Properties of Thermoplastic Composites Obtained by Large-format 3D Printing Process

Miguel A. Hidalgo Salazar, Professor, Universidad Autónoma de Occidente
The process of large-format 3D printing is gaining popularity because larger pieces can be obtained in comparison to the conventional 3D printing process, being a promising alternative for products design and development due to the incorporation of innovative raw materials as biocomposites for large scale manufacturing. In this work, tensile test specimens were 3D-printed by large-format process and different commercial material used in conventional 3D printing. As-printed specimens and annealed specimens were subjected to tensile testing. DSC and TGA were used to optimize the printing process and annealing conditions of the samples. It was observed that the annealing process had a different effects on the properties depending on the materials studied.

4:00 pm – 4:30 pm:
Yes, You Can Break Certain Design Rules and Still Have a Successful Product – a Logical Look at the Implications

Vikram Bhargava, Author, Trainer and Consultant
Plastic parts are a lot less forgiving than their metal counterparts on the strict adherence to established design rules for meeting short and long-term performance requirements. These requirements can broadly be broken into: Cosmetics Impact strength Toughness Chemical resistance Tolerance precision High and low-temperature use and cycling Outdoor exposure Cost Thus, a much more rigorous adherence to the rules may be required for a high-end handheld, mission-critical computing and communicating device in a hospital that needs to be cosmetically appealing, have very high impact strength, good chemical resistance and high and low-temperature resistance. A failure due to design errors in a simple drop on a device like this in the hand of a medical technician may cause death! On the other hand, a minor blemish or crack in a lightweight remote control for a low-end TV may not nearly be as catastrophic. The base cover of an inexpensive, lightweight inkjet printer may be even more forgiving. To be realistic, design rules may have to be broken based on the end use and other conflicting product requirements. This paper will provide a logical guide on making exceptions to the design rules based on multiple case studies. It will also introduce a design checking software, DFMPro where the rigorousness of the design rules can be “dialed” in based on the specific product requirements.

4:30 pm – 5:00 pm:
Polypropylene/ Polyvinylidene fluoride Fibrous Water/Fuel Filters Produced by a Unique Multilayer Co-Extrusion Process

Cong Zhang, Case Western Reserve University
A unique co-extrusion and multiplication technique combined with a water jet fiber separation process was utilized to manufacture nano/micro-fibrous filters for applications in fuel/water separation. Hydrophobic polypropylene/polyvinylidene fluoride (PP/PVDF) dual-component fibrous filters were produced having different fiber size. The filter pore size was found to decrease with decreasing fiber size and the surface area was found to increase with increasing fiber size. The filter having the smallest pore size exhibits the highest filtration efficiency as 93.5%. Corona treatment was conducted on the PP/PVDF fibrous filter to evaluate hydrophilicity influence on water separation. It is found that moderate hydrophilicity improves the water separation efficiency.

5:00 pm – 5:30 pm:
Technical Evaluation of Loctite HY4060GY: The Ideal Replacement for Traditional 2K 5-Minute Epoxies

Matthew Miner, Henkel
Loctite® HY 4060GY™ is a 1:1 two component cyanoacrylate – epoxy hybrid adhesive which makes up part of the new range of Loctite® universal structural bonders launched in March 2017. These innovative products are powered by a patented hybrid technology that combines the most critical attributes of cyanoacrylate and structural adhesives. Loctite® HY 4060GY™ offers durable properties with fast time to develop handling strength in a 25 ml ‘ready to use’ pack with integrated plunger making it an ideal replacement for traditional 2K 5-minute epoxies. This paper presents the performance of Loctite® HY 4060GY™ against a number of Henkel and competitor 2K epoxy adhesives.

5:30 pm – 6:00 pm:
Utilizing Should Costs to Engage Millennials in the Workplace

Laurel Bougie, Customer Success Manager, aPriori
The gap of skilled workers in manufacturing is expected to grow to two million workers by 2025 and millennials will make up 75% of the current workforce. Without focusing on the shortage the industry as a whole will face, there is a looming challenge many of us are already facing today, how do we attract and retain the millennial talent we already have? Forbes has noted that the number one reason millennials leave their current role is lacking a sense of purpose in their work. Deloitte has gone so far as to coin the term “purpose gap.” Millennials are not satisfied with the excuse of “that’s how it’s always been done” and have begun pushing back on inefficiencies within the workplace and asking for transparency. In this session, you will learn how the implementation of aPriori’s should costing tool can bring purpose back to your design engineers, cost estimators, and procurement teams. This tool provides real-time feedback and provides transparency surrounding part costs that allows millennials to make data driven decisions surrounding cost throughout the product life cycle and translate the impact of their contributions to the overarching company initiatives. aPriori’s Cost Insight Business analytics tool also allows for the slicing and dicing of should cost data to support business decisions and provides an overarching product cost management solution that will re-engage your millennials so you can focus on pipeline talent for 2025, not immediate back fills.