Injection-moulded bracket, design for manufacture

A coursework part taken all the way to a real tool, which is where you find out what your CAD was hiding.

University

Bracket 01 parts

The exercise was to take one bracket from sketch to moulded part on the department's bench press. Mine held a sensor on a frame, so it needed stiffness in one direction and almost none in the other.

The first tool gave me sink marks exactly where I had been warned they would appear. Version two moved the boss off the thick section and added a rib, which fixed it. Wall thickness stayed inside 2.0 to 2.4 mm across the part.

I kept every reject on my desk for a term. They are better teachers than the good ones.