DUCKY GO-GO: DUCK KEYCHAIN

Processes: Injection Molding, CNC Machining & CAM, DFM/DFA, Statistical Analysis

Project Brief

In 5 weeks, design a part or family of injection molded parts that:

  • demonstrate some functionality — whether it be useful, artistic, or otherwise interesting

  • interact in a geometrically specific and meaningful way with multiple copies of itself / themselves

  • AND / OR connect with an existing part or assembly

Challenges

  • Modeling multiple complex, organic forms in CAD

  • Determining the best assembly design and molding strategy such that the body could have a large, round volume with limited sink

  • Figuring out how mold otherwise unmachinable features using shut offs and inserts

  • Accounting for material shrink with statistical analysis

Results / Takeaways

A very hard-earned success that seemed at first unattainable!

  • The duck body is charmingly rotund and has no visible sink thanks to insert- and overmolding strategies

  • Statistical analysis proved extremely effective in ensuring that shrunken parts fit in the mold with no gaps during overmolding and fit perfectly together

  • Enhanced confidence in CAD, CAM, and molding