Goals

Enhancing Accessibility to Advanced Prosthetics

The primary goal of this project was to create a reliable system for printing incrementing and production data onto PET foam blocks in a high-speed manufacturing environment. The system needed to integrate an inkjet printer with the production line, ensuring accurate, consistent, and legible printing on every block. A custom-designed mount was required to securely attach the printer to the line, enabling precise positioning and seamless operation.

Another objective was to improve operator interaction with the system by addressing challenges related to block flipping during the cooling process. To achieve this, a mirror and light system was incorporated to reflect the printed data for operator inspection without disrupting production. This enhancement aimed to streamline quality assurance while maintaining efficiency and reducing downtime.

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Prototyping

Creating a Versatile and Collision-Resistant Design

During prototyping, multiple design concepts for the printer mount were developed and refined. These prototypes featured adjustable handles and mechanisms to simplify alignment, ensure secure attachment to the production line, and allow easy cartridge replacement. The designs prioritized collision avoidance and incorporated safety features to protect both the printer and nearby equipment during unexpected impacts.

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Expansion

Improving Usability and System Documentation

The project expanded to include the addition of a mirror and light system that allowed operators to inspect printed data even after the blocks were flipped in the cooling tower. Comprehensive work instructions were developed to standardize system operation and maintenance, ensuring consistent performance. Safety stickers were added to critical components, and the printer program was updated to improve reliability and accommodate future production needs. These enhancements bolstered the system’s long-term safety, usability, and adaptability.