ESCO-Nestable Crate Paul Silver Gary Hicks Chad Freitag Anwar Al-Alawi

Design Brief The project was to design a reusable crate that would be collapsible, stackable, and/or nestable, such that it can be returned to ESCO once the product has been shipped using minimal cargo space.

Four Step Process Product Design Specification External Search Internal Search Concept Evaluation & Decision Each step applied to all major components of project

Design Concept Return, Nested Outgoing, Stacked

Sizing/Proportion Analysis Must fit logically/spatially into 20’ cargo container Packing density of 55-gallon drum Spacing around crates for easy movement with forklift Crate size/proportions computed 20 crates per 20’ cargo container

Sizing/Proportion Analysis

Material Selection Durable, lightweight, recyclable Low maintenance Exposure to harsh environment Commonly available Proven performer

Material Selection High Density Polyethylene (HDPE) Structural foaming agent Opportunity to learn about plastics

Chest & Lid Geometry GE Plastics - Injection Molding Guidelines EDS IDEAS - solid modeling

Chest & Lid Geometry

Chest & Lid Geometry

Structural Analysis EDS IDEAS CHEST Maximum Von Mises-3900 psi Maximum deflection-0.139” LID Maximum Von Mises-3750 psi Maximum deflection-0.323” COMBINED WEIGHT - 176 lb

Structural Analysis HDPE yield strength - 4800 psi Chest Lid Safety Factor - 1.23 Lid Safety Factor - 1.28

Structural Analysis

Structural Analysis

Structural Analysis

Manufacturing

Manufacturing Low Pressure Injection Molding Aluminum tooling vs. steel tooling Aluminum is less expensive and requires less lead time Influence on design process

Economic Analysis Crate vs. 55-gallon drum Drums - $9 Crate - $187 Based on 5-year span Drums - $302,400 Crates - $478,720

Economic Analysis Crates cost more Difficult to place price on long term environmental savings What are you willing to pay for environmental preservation? Salvage value - can be used for less strenuous tasks Storage Material movement

Rapid Prototype PSU rapid prototype machine Verify nesting ability Verify stacking ability

Further Development Design optimization Different loading conditions Reduce weight Decrease stress concentration Different loading conditions Impact Crane straps Quotes for initial production run

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