Picature

Project duration

6 Weeks

Fall 2024

Materials

Dynaflix

TPU

Fabrication methods

Injection Molding

CNC

3D printing

key skills

Mold Design

Material Testing

Moldflow Simulation

Interlocking Design

A playful, cat-shaped picture holder engineered from a single material. It leverages two key properties of Dynaflex TPE: its elasticity allows the pieces to bend and interlock with one another, while its natural surface grip holds photos securely in place without any clips

For my final project in the Making Multiples course at Stanford, I wanted to redesign a multi material product into a monomaterial alternative making it recyclable.

As I was looking for a product to redesign, I noticed this picture holder that my friend Laura was using. It had 4 different materials: A wooden clip with a steel spring.

After initial sketches, I started modeling in CAD and prototpying a series of iterations using PLA and TPU.

I move through 11 iterations in 3D printing and 4 iterations in injection molding to land on the final design.

After testing, I landed at a robust design concept that worked in TPU (the PLA in the middle is just hanging there).

‍

Evelution of CAD design: 

The cat was modeled after my cat, Fawaz. In the final design Fawaz's head and hands are over-molded over the body of the holder.

No items found.
Injection Molding Simulation: 

I simulated multiple gating options for the first part and ended up gating from both sides.

The simulation showed possible areas of sink and weld lines that where eventually going to be molded over.

No items found.

For the head and hands, I gated from the top middle.

I needed to adjust the wall thickness underneath the hands to avoid possible sink

No items found.
Machining the molds:

I had to machine one mold for the first part, and one for over over molding the head and arms.

First mold:

No items found.

First iteration of second mold:

  • The part sat two low in the mold which led to material leaking to the middle part.
  • Hands didn't fill well
No items found.

Second iteration:

  • Machine a curve into the top piece to hold the middle picture holder tighter and lifted it up compared to the first iteration.
  • Changed the finish on the hand and increased gap for plastic flow.
  • Change finish on the face and hands
All Projects