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

2. 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.

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

4. Design Concept
Return, Nested
Outgoing, Stacked

5. 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

6. Sizing/Proportion Analysis

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

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

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

10. Chest & Lid Geometry

11. Chest & Lid Geometry

12. 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 lb

13. Structural Analysis HDPE yield strength - 4800 psi Chest Lid
Safety Factor
Lid
Safety Factor

14. Structural Analysis

15. Structural Analysis

16. Structural Analysis

17. Manufacturing

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

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

20. 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

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

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

23. Conclusion
Add a strong statement that summarizes how you feel or think about this topic
Summarize key points you want your audience to remember