1. Feasibility Analysis P14415

2. Thermoforming Quote- CJK

3. DIY Vacuum Forming Use kitchen oven to heat plastic Use shop-vac with vacuum box shown Build vacuum box for under $100 Shop-vac costs $69-$299 External Heat source possibility Quote for New and Used Machines

4. Purchasing Vacuum Forming Mach. Cost: $12,900 http://www.belovac.com/

5. ABS vs. Polycarbonate P olycarbonate Pros: Outstanding toughness Good optical clarity Strong and stiff Easy to fabricate Easy to solvent bond Cons: Expensive compared to ABS Good resistance to UV with stabilizers Thermoforms well after drying ABS Pros: Outstanding impact resistance Good machinability Easy to thermoform Easy to bond with adhesives Strong and stiff Low cost Cons: Poor UV resistance Becomes brittle with UV stabilizers

6. Material Eliminations: Acrylic: Brittle Polyethylene (HDPE/LDPE): Poor material strength properties compared to ABS Polycarbonate: Expensive relative to ABS (2x the cost for most sheets) Curbellplastics.com

7. Material Research References: http://www.morganclaypool.com/doi/pdf/10.2200/S00184ED1V01Y200904MRE001 http://plastruct.com/Pages/Properties.html http://www.toolcraft.co.uk/vacuum-forming-material-specs-abs-hips-hdpe-petg-pp-pvc.htm http://www.machinist-materials.com/comparison_table_for_plastics.htm http://www.curbellplastics.com/technical-resources/plastics-properties-table.asp?cols=&compare=1,2,6,8,16,17,21,23,24&direction=desc

8. Design 1 Models

12. Ansys Analysis - Design 1 Summary Max Stress: ~1.5x Ultimate Strength Values Too high of stress values for fairly conservative model of worst case Design is insufficient as is to move forward with Needs redesign with added strength from additional supports: metal

13. Ansys Analysis - Modeling Summary Worst Case and Normal Usage Multiple Discussions with Dr. Boedo and Dr. Debartolo Worst Case: Load (270lbs) around hole Normal Usage: Load (270lbs) across two locations at normal stance width Only base modeled, without material thinning Iterative solution modeling

14. Ansys Analysis - Results Summary

15. Design 1 - Stresses: Normal Loading Circles denote peak stress locations.

16. Design 1 - Deflection: Normal Loading

17. Design 1 - Meshing: Normal Loading

18. Design 1 - Stresses: Normal Loading Circles denote peak stress locations.

19. Design 1 - Deflection: Normal Loading

20. Design 1 - Meshing: Normal Loading

21. Design 1 Feedback

22. Ansys Analysis - Conclusions Stresses too high for a fairly conservative model Redesign required with additional supports, such as rebar Debartolo believed analysis and conclusions seemed valid

23. Design 2 - Analysis Assumptions Rigid supports for deflection between ribs Cantilevered rib bending

24. Design 2 - Analysis Deflection between rigid supports

25. Design 2 - Analysis Deflection of Ribs

26. Design 2 - Analysis

27. Design 2 - Feedback Dr. Debartolo Assumptions inappropriate Need to assume ribs pinned, not cantilevered Need to assume deflection between ribs is cantilevered Distributed load will reduce deflection between ribs

28. Design 2 - Moving Forward Redo calculations with new boundary condition assumptions Possibly change material based on new analysis

29. Shipping Costs- Miami To Haiti (Preliminary Analysis) -Analysis of per unit cost if container is filled to capacity -Assumptions: - One day storage before loading and after unloading (2 days total) - Weight does not affect cost - Cost per part is determined by volume

30. Shipping Costs- Data

31. Shipping Costs- Calculations

32. New Risks Risk Chart Entry: