Screwdriver
Task: Design an ergonomic pocket sized injection molded Vydyne 41 Black High Impact Nylon screwdriver handle with a Philips head 89 mm long core.
Objectives
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Adhere to specified constraints (volume, dimensions, Wera PH#2 blade incorporation, over-molding)
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Develop a 6061-T6 Aluminum injection mold compatible with the Morgan injection Molding Press, applying Design for Manufacturability (DFM) principles.
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Fabricate the mold tooling using HSMWorks for CAM programming and a Haas VF-2 CNC mill.
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Produce functional prototypes via injection molding to validate the design and process
Design
The inspiration behind the design comes from a golf wrench tool, which is commonly used by golfers to adjust driver head and shaft combinations
Keys to Success:
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Uniform wall thickness
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Account for shrinkage as part cools
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Incorporating ribs for strength,
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Adding draft to all vertical walls for mold release
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Avoiding undercuts​​​
Manufacturing
I used an HSM to map and plan tool 3 axis paths and create a tooling library to machine the top and bottom mold halves.​
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Post processed to a Haas VF2 to create NC code and added a sub routine M98 P100 for probing the material to locate the G54 in the machine offsets.
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NC files were saved onto a USB drive and inputted into the Haas VF2 for machining.
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Final Product
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I successfully achieved the core objectives of this project and produced an ergonomic over molded Phillips head screwdriver
