Final Design Improvement Of Replica Trophy From Prototype To Mass Production
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Date
2022-07-01
Authors
Tan, Sher Wen
Journal Title
Journal ISSN
Volume Title
Publisher
Universiti Sains Malaysia
Abstract
Trophy serves as a recognition and a reminder for a specific achievement. Most of the
replica trophy is designed based on the theme of the event. Therefore, reverse engineering
is the most suitable way as it transforms real parts into engineering models and is widely
used in manufacturing industry. In this paper, it is required to improve the design of the
trophy for mass production based on the event of Hall of Fame Universiti Sains Malaysia
(Sanggar Sanjung) to celebrate the success of staff. The objectives of this paper are to
identify current trend with improvement of functionality and determination of cost saving,
time saving and quality improvement in order to produce the final design of replica trophy
in mass production. Function analysis and FMEA is conducted to analyze the failure mode
effect of the prototype. Few concepts are generated and is further analyzed in the
morphology chart. After the concept generation, material and manufacturing process is
selected for each part. 3D scanner is used to scan the object (hand) and the data acquisition
is obtained by the scanner. The scanned results are discussed to get a better output. The
surface finish of 3D printed hand structure is discussed and solved by sanding process. By
using the CATIA simulation, suitable toolpath, speed and tool is selected to preview the
machining time and output of the part of trophy. This approach can lead to short time
consuming as it reduces the error during CNC machining. Then, the selected parts are
fabricated by the CNC machine and 3D printing respectively. The cost for fabricating a
single trophy and mass production is compared and it can be concluded that mass
production of trophy can reduce the costing with RM93.86 whereas single production is
RM187.54. Lastly The time taken for single trophy is 12.20 hours and 10 trophies is 11days
which is simulated by Witness Horizon software.