Hard-Hat Clipable Safety Notification System (#2)

Thank you everyone who submitted design entries! Congratulations to the 1st place prize winner Vivek for submitting a very attractive and manufacurable housing design. He made multiple submissions and worked very hard meet my requests. Congratulations to Peter for 2nd place prize for a very aesthetic and creative design. He also redesigned multiple times to meet my suggested changes. And lastly, congratulations to Indrawan for a very creative and manufacturerable design. He has a very creative and artistic design, and probably the most aesthetic clip design.

I'll be sending a more detailed score sheet out to everyone soon!

Hi all,

Thank you so much for the submissions! I'll grade the entries over the weekend, attach a grade sheet, and select winners.

Great contest ! Thanks ! Once i receive your answers I'll update my design and resubmit.

Do you know what the estimated annual usage on this product is, so that I can designed around a P20 steel tool, or a hardened H13 steel tool ?

If the USB port is to be made with a mechanical slide in the tool, then you'll need a hardened steel mold. The USB port cutout can be made with an open and close mold, but I don't know what your tooling budget is.

Is it ok to design around a PC/ABS material ?
Do you need it to be at a particular UV rating for this application ?

are you going to use ejector pins in the mold, or will this part need a 3 plate tool design.
Please let me know before the contest ends so that I can submit a proper design.

oh, one other thing. is there a particular location that you would like the parts gated into ? This affects the design as well and I'm assuming that you don't want a big ugly gate scar on the housing from an operator using clippers to cut it off.

Do you want it subgated or tab gated ?

thanks.

Hi, I need some more time.
I'm working on ribs that are to be used as board supports and I'm not sure what thickness to make them without causing
ugly sink marks on the outside of the housing. I'm sure others have already considered this, but I haven't seen comments on it.

Can you provide some assistance on what the housing wall thickness should be, and what the rib thickness should be ?
I'm assuming that there is some sort of cosmetic specification that needs to be considered in the design.

Also, are you texturing these parts ? What draft angle should I use and what is the Mold Tech specification you plan on using
for texture if infact you are going to want texture.

Also, is it ok to use multiple slide mechanisms in the injection mold. These increase your mold cost 30-40% and I want to make sure my design is in line with your tooling budget.

Thanks.

Some more time would be nice! Thanks!

Yes.

Hi Everyone,

Does anyone need more time with their designs? If two or more people do, I'll extend the project for 3 days.

Hi Everyone,

Here is some material to help everyone with manufactuability and making models compatible with plastic mold injection:
- https://www.stratasysdirect.com/resources/injection-molding/

Hi khan,

Solidworks is fine. Just be sure to submit .stl files when you're complete with you design so we can 3D print your design.

Dear Sir,
Can we use solidworks 2016?
Regards,
Munawar khan.

Hi MAINAK,

If anything, I'll extend the competition if everyone needs more time.

Please don't close this competition before deadline.

Hi Idham,

Please build the housing exactly to the PCB specifications and 3D models.

the PCB design must be same with the attachment?

Hi VM,

There is a 0.5 mm tall micro-controller. Please model 0.5 mm of clearance for the bottom of the PCB.

Thanks, I had already modeled the PCB in 3D, but it would be nice to have your file in .dwg or .dxf file (saved as 2010 autocad version), just to compare. What troubles me more, though, is the clearance between the bottom face of the PCB and the case. I've gone with 2mm clearance, as I guess there's no electronic component of significant thickness at the bottom of the PCB ( e.g. like the thickness of the battery, on top of the PCB)