New Product Development of Additive Manufacturing

Project done as part of the course 24-632 (Additive Manufacturing Processing and Development) at Carnegie Mellon University (Fall 2022)

The creation of a highly customizable gear shifter/emergency brake shift knob using additive manufacturing was the focal point of the team's design project. The customizability, which allowed users worldwide to provide their hand's impression through depth cameras for a personalized design, formed the unique selling point. The integration of complex gyroid structures and the offering of material choices like TPU aimed at targeting a niche market. Responsible for Design of gyroid structure, slicing STL file and printing using FDM machine (Stratasys F170).

Design iterations were undergone by the product, evolving from a solid body to a gyroid-based structure, optimizing weight, and structural integrity. The gyroid density was strategically increased in areas of higher grip pressure for enhanced strength and user comfort. Material choices and mesh structures were customizable, with an option for a transition from solid to mesh. The complex geometry necessitated SLA-based printing for successful production, involving Stratasys F170 with dual extruders for support material.

The final printed prototype showcased the intricate gyroid structure, providing a tangible representation of the innovative design. A unique business model was offered, catering to a low-volume, highly customizable market. Despite challenges in lead time due to the intricacies of mesh refinement and complex geometry, the product was deemed successful. The business model competed by providing a polymer for grip, distinguishing itself from theme-based, less customizable competitors.

Challenges, particularly in lead time and the complexity of mesh refinement, were acknowledged in the retrospective analysis. The effectiveness of the iterative approach was highlighted in balancing design complexity and print time. Consideration of trade-offs, such as orientation changes affecting build times, was emphasized in the discussion. Reflections on the initial model creation and potential exploration of a broader product idea list for future projects were discussed.