USB in the USA Tyler Joseph Reimer, Sang Jun Han, Lukas Shaw Smugar, Alexa Marguerite Trautz

Outline Mission Statement Background Criteria Initial Ideas Mock 1 Testing Mock 2 What we’ve learned Conclusion

Mission Statement Assist Lockheed Martin (our customer) in designing new Hub Bracket Minimal part count Hold 7 port Hub Maintain cable retention under high frequency 4 point screw mounting Minimize addition screwing Vertical mounting optional

Background (In the olden days) Original 3 Parts Requires many screws Not additive manufacturing Dual Stack 4 Parts Requires more than one bracket Lots of screws Not additive manufacturing Old Hub and Bracket

Why switch to the AM? Less waste from production of parts Simpler builds with less separate pieces Rebuild anywhere (With access to printer and computer) Quick and easy to make adjustments The world is your oyster Multiple Materials in one part

Criteria Could be both vertically and horizontally mounted. Holds 7-port D-link USB Hub. Has less than 3 parts. Successfully support the USB wires so they maintain connection under high frequency.

The Decision Process Clamp Locking Bracket Rotating teeth that secure USBs Clamp that secures on top. Lots of moving pieces Many parts Rubber Holding Bracket Outer plastic shell Screws into place Inner rubber case Rubber case extends to hold USBs 1 parts Multistack Super Bracket Removable Top Tightens on top of port Rubber lining walls Can hold multiple brackets. 4 parts

Decision Matrix Beats: 2pts Meets: 1pts Fail: 0pts

Purple and Blue: Mock 1 1 part Rubber with plastic case Stackable Supports USBs with rubber lips 4 mounting holes

Let’s get testin’ Vertical Mount Test Shake Test Assembly/Disassembly Test Cost Evaluation

Vertical Mount Test Bracket with USB was mounted both vertically and horizontally against a piece of wood. The USB and cables did not fall out in either situation. SUCCESS!

Shake Test Bracket mounted against wood Clamped to a shake machine. Subjected to min, medium and maximum frequency. Maintained in tact with USBs over long time period of shaking. Results: Avg. G-force- ( ) Max G-force- (3.466) Min G-force- (.026)

Shake Test Pics and Video

Assemble/Disassemble Test Bracket and Hub were fully assembled and screwed into wood piece while being timed. Bracket and Hub were fully disassembled and screwed out of wood piece while being timed. Results Time Assemble (s)Time Disassemble (s) With Drill With Screw Driver

Cost Evaluation Time to print: 8 hours Operation cost: 8hrs *$3=$24 Purchase Price: (1000*8)/(.95*24*365*3)=$.32 Material cost: $1.80 Labor: 1hr*$10=$10 Total: P+O+M+L= $36

Alterations Made Afterward Extended the rubber to hold more of the USBs. Adjusted edge to assist in assembly and disassembly time. Wrapped rubber around bracket for firmer fit.

Solidworks Mock 2 Build Time: 8 hrs Similar design to Mock 1 Extended rubber lips to contact USB better The mounting tabs were extended to improve ease of assembly and disassembly

What we’ve learned “We can send a USB (with our bracket) into space” -Sang How AM hindered us... Careful consideration was needed in geometry of print The time to get printed was sometimes very long Designer has to be solidworks proficient

To Summarize... Lockheed Martin requested a new USB Hub Bracket built with additive manufacturing. We created a simplistic design that did the job. 1 part. Held wires under high g-force. Easy to assemble and disassemble Recommendations: The plastic shell used in testing was strong when paired with the rubber inside. A metal shell was not tested but could be a better option for your needs. If you stick with plastic rubber combination, use Material Extrusion

References ●"7-Port USB 2 Hub." 7-Port USB 2.0 Hub (DUB-H7). D-Link, Web. 26 Apr ●"G-force." Wikipedia. Wikimedia Foundation, 7 Apr Web. 26 Apr ●"Annual Report." Our Businesses · Lockheed Martin. Lockheed Martin, Web. 26 Apr ●"EDSGN 100, Section 026: INTRO ENGR DSGN." EDSGN 100, Section 026: INTRO ENGR DSGN. Lockheed Martin Customer Team, 28 Mar Web. 26 Apr