Golf Prosthesis Final Design Report (P9)
Bill of Materials
Table 2 below shows our total materials cost to manufacture our prototypes and forearm attachment.
During the design process Jim Taylor traveled to San Luis Obispo from Longview, WA twice during the course of a year. Below is a table showing the price for each trip Jim took to San Luis Obispo.
Process Once our designs were finalized, we began researching various processes for manufacturing. From the beginning we knew we would need to test different materials in order to select the most appropriate one for our designs. We contacted Smooth-On, a mold making company located in Los Angeles, who helped us select the best material for our application. They suggested proceeding with a soft plastic material or polyurethane. In order to make our designs with these materials we first needed to create a silicon mold.
In order to create a silicon mold a prototype was necessary. After creating each design in Solid Works, we used the rapid prototype machines available on campus to create a model out of ABS plastic. Once the model was finished, we created a mold box which we filled with clay as seen below in Figure 26.
The plastic model was submerged halfway into the clay leaving only half of the model exposed. Next we added a compound Silicon mixture provided by Smooth-On. Once the mixture dried, we flipped the mold over, removed the clay, then added additional Silicon mixture to complete our two-part mold. The idea of the two-part mold was to have a reusable mold that can be separated down the middle for easy access. The biggest issue with our mold was the complexity of shapes of our final designs. The models we created have numerous crevices where air can get trapped and the Silicon will not reach. After numerous attempts to perfect the two-part mold, we finally decided to pursue other options.
Once our attempts to create a two-part mold failed we were left with few available options. Fortunately, we discovered that the Mechanical Engineering department has UV Resin rapid prototypes available for student use as well. Unlike the standard rapid prototype machine that uses plastic, a resin is used for the UV Resin machines. The resin material is a much stronger material than ABS plastic but also sustains a measurable amount of flexibility. With time running out and ideas running thin we decided to manufacture our final designs with the UV Resin machines.
The machines took between 8-16 hours to completely render our designs. This proved to be a great asset as we continued to iterate and alter our final designs. For our two final designs, three UV Resin prototypes were manufactured for each. Below are the final renditions of both the golf sleeve and cuff designs.