Andy Feig

1

• Andy Feig
• Sonia Khaira
• Adam Lusin

Liz Urish Jim Weiland Brad Young
Business Partners Michael Zanan and Rob Kameen
2
Final Prototype

• A wooden box was used to create a housing for a
  mold
• Silicon rubber was used to create a mold to make
  the pewter metal prototype
• Several attempts were needed to create a
  prototype of acceptable quality

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Final CAD Models
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Final Manufacturing Plan

• Each piece will be prototyped once using
  stereolithography
• The prototypes will then be used to create a
  rubber silicon mold
• Pewter is then poured into the mold to create the
  piece
• The final product is then subjected to finishing
  machining and polishing

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Final Manufacturing Plan

• Board and Box were cut to size specifications
• Board trim and box notches were then cut for
  assembly
• Box and board assembled, glued, and secured with
  a box frame
• After drying, joints were secured with brads
• Wood putty was used to fill holes and final
  product was sanded to desired smoothness
• Fake paper board was produced to give the feel of
  a chess board

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Bill of Materials and Cost Estimates
Queen Piece Prototype

• Queen SLA Prototype 294. (market price)
• Wood for mold housing 2.94
• Contact paper 0.39
• Silicon Rubber 3.12
• Pewter 8.40
• Miscellaneous 2.00
• Total 310.85

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Bill of Materials and Cost Estimates
Chess Board Prototype

• Wood 21.00
• Wood Putty and Nails 4.00
• Total 25.00

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Future Considerations

• Mold investigate use of vulcanized rubber molds
  instead of silicon rubber.

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Future Considerations

• Use common casting techniques to reduce cost of
  production
• Cores
• Risers

• Multiple patterns per mold
• Dr. Voigt

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Future Considerations

• Ceramic tile is too heavy and problematic
• We need to find an adequate material for
  checkerboard design
• Aluminum
• Mosaic Tile
• Wood
• Any suggestions?

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What have we learned?

• The challenges of bringing a product from design
  to manufacture
• How to compromise to reach agreements on design,
  manufacturing, and responsibilities
• How to use Pro-Engineer, MasterCAM, Microsoft
  Project, and have come more familiar with CNC
  Machining and Casting
• Liz can use a bandsaw

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Gathering Information

• We learned the benefits of having a backer
  (College of IE) to support design costs and
  difficulties
• Use all human resources available
• IME Faculty
• Dr. Voigt
• Lowes Tile Guy
• Local Business
• Business Partners
• The Internet is our friend.

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Surprises

• How the design process was changed by
  manufacturing requirements
• The complexity in both machining and casting
• The wide range of manufacturing processes
  available

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What business students taught us

• How the business aspects of a project can
  influence the design and manufacturing processes.
• Made us aware how the entire cost of production
  to distribution affects the total revenue gained
• Without a market, a product cannot survive.

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What are they saying about the Chess Set?
Those kids are Pro-Excellent!
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What are they saying about the Chess Set?
Yo, Simpson! Give them kids an SLA !
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What are they saying about the Chess Set?
This chess set is at MMC Maximum Memorabilia
Coolness!
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What are they saying about the Chess Set?
Ill follow these winners all the way to Café 210!
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What are they saying about the Chess Set?
Someday, these kids will earn enough money to
dress as sharp as I do!
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Questions