Zip Tie Connector
The objective was to design and manufacture a 3-way connector for joining zip ties, ensuring high strength, low production costs, and a mold design that avoids complex side pulls to maintain a 50% profit margin.
My Role in the Project
I led the design and engineering process, conducting design for manufacturing (DFM) and design for assembly (DFA) analyses. I created the mold design, prototyped to validate functionality, and oversaw the manufacturing process to ensure quality.
Target Users and User Testing
The target users are industrial workers, DIY enthusiasts, and manufacturers who require a reliable, cost-effective solution for securing multiple zip ties in applications like cable management or construction.
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Initial tests showed minor mold release issues, which were resolved by adjusting draft angles. Users reported the part’s strength exceeded expectations, but some requested a smoother aesthetic, which was achieved through refined wall thickness and rounded edges.
Preliminary Work and Challenges
I conducted draft analysis and researched mold designs to avoid CAMs or hydraulics. Initial prototypes were 3D-printed to test fit and strength, and DFM/DFA analyses ensured manufacturability and assembly efficiency.
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The primary constraints were eliminating side pulls in the mold to reduce manufacturing costs and ensuring the connector could withstand the yield strength of zip ties. Aesthetic appeal and part thickness also needed to meet customer expectations.
Final Product and Discussion
The final 3-way connector is a robust, injection-molded part that joins zip ties securely without requiring side pulls in the mold. It meets strength requirements, has a sleek aesthetic, and achieves the targeted 50% profit margin.
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This project honed my skills in DFM and FEA, emphasizing the importance of early analysis to streamline manufacturing. The success of the connector validated my approach to balancing cost, strength, and aesthetics, delivering a highly functional product.
