CAD Modelling and Manufacturing Quality Verification

The project was to choose a relatively complex bottle to model and then test the models manufacturing feasibility.

Initially we were taught some more complex modelling techniques to create some tough geometries.
Next came shape analysis which involved reflection analysis and radius analysis. The former tests surface quality to testing smooth continuation of lines across multiple surfaces.
Radius analysis was done to find the different radii in the model and therefore then the mould. The smallest radii tend to cause issues in manufacturing so these were the main focus.
Based on the fabrication machinery available I compared the smaller radii on the design to the smallest ball milling diameter and found a slight redesign was needed to avoid post-processing.

After this analysis, the mould cavity was designed, then analysed to make sure the radii in the mould were not too small to manufacture either.

Following this, the simulation of manufacture of the mould was done using a variety of ball mills and finishes to see which rendered the best result.

Finally, the mould was exported to Vericut to verify that the manufacturing process selected would work properly. Tolerance analysis was done with 0.2mm excess tolerance, where minimal gouging was observed in the simulation.