Sustainapack SDD Rev B

grabcad

This revised entry focuses on modifications made to "sustainapack entry SDD". The changes include adding a cardboard box (FIG 1) and two foam pads, resulting in packaging for 200 low pressure switches. Arranged in a 5x5 matrix, the switches are positioned into pockets of injection molded trays, extended on one end by 25mm and stacked eight layers high with alternating flats rotated 180 degrees (FIG 3). This design allows for a tray height of 43mm per layer, saving 20.6mm per layer compared to the previous part height. The foam pads in the bottom of each pocket apply pressure to switches without damaging sheet metal brackets (FIG 5), while vertical weight is distributed through the tray legs. Although further refinements could be made, a mold flow analysis and FEA are recommended for optimization. The current design has a scrap-to-product ratio of 51.5%, which should ideally be around 25% or lower. Mixing regrind material with filler at 50-70% could potentially help achieve this target. This project presents significant challenges but offers opportunities for improvement.