Design Portfolio Cam Hardman, Laura Tuck , James Veale

1

Overview “PolyPack is our innovative solution to creating beautiful, sturdy and environmentally sustainable

packaging.”

The packaging consists of a

soft fibrous interior

transitioning to a hard

plastic shell to provide

twofold protection.

The PolyProducer converts

shredded PET—sourced

from plastic bottles—into an

impact resistant, fibrous

material using a process

inspired by candyfloss

machines.

The PolyPacker uses

heated moulds to

add a rigid,

customisable outer

shell to the

packaging.

Table of contents

Overview

Inspiration and Existing Products

PolyProducer - Initial Prototyping

PolyProducer - Further Prototyping

PolyProducer - Final Iterations

PolyProducer - Final Design

PolyProducer - Exploded View

PolyPacker - Initial Design and Prototyping

PolyPacker - Prototyping

PolyPacker - Further testing

PolyPacker - Final Design

Product Analysis

Packaging Analysis

Presentation Drawing

2

Inspiration & Existing Products Candy floss machines : the inspiration for the raw material Packaging inspiration

Candyfloss machines: The process of

producing candyfloss is very simple: sugar

is inserted into a spinning central pod. As it

melts, it is flung out of small holes to

create thin fibres. The raw material can be

sugar, boiled sweets, Our concept was to

recreate this using recycled plastic as the

raw material

Polyfloss fibres: Fi-

bres seen online were

rough and unappeal-

ing—this may be im-

proved with parame-

ter optimisation

Housing insulation: More sophisticated

plastic fibres are used in insulation,

suggesting this floss material may have

insulation properties

Sanguine perfume

bottle: packaging

design is often a major

selling point of high

end perfume

Prior art: This idea had already been

exploited by a firm called Polyfloss. They

use PP to make fibres which are used for

craft purposes. We believed this could be

applied in a more practical setting

Existing applica-

tions: often use

hot plates to form

hard layers from

the flossy materi-

al

Existing Polyfloss machine: designed mainly

for aesthetic purposes and an art/craft

setting. This design could be improved for an

industrial setting

It was suggested that the combinations of soft interior, hard

shell and insulation properties could be utilised in packaging,

to reduce the environmental impact of current solutions such

as EPS

Original candy floss patent:

Existing candyfloss machines can

be seen in patents for inspiration:

-Central pod contains rows of

holes to increase production rate

-Heated with elements using

brushes and slip rings because

the bowl rotates

-Opening required in bowl to

allow material to be inserted

Apple: known for making its

packaging “part of the expe-

rience” of purchasing an Ap-

ple product

Devotion ring box:

Jewellery is a high-end

product focussed highly on

fashion and aesthetics

Graze delivery box:

an increasing number

of firms operate

online only and

packaging forms a key

part of their brand

management

Coke bottle:

packaging has

the ability to

become an

iconic part of a

brands identity

Equilateral soap:

using shape to

convey brand

identity

Asylum CD cover: using

texture to draw attention

Nike air: novel material

used to give brand

identity and draw

attention

Colier sparkling wine:

make opening the

product a “grand

reveal” to add to

enjoyment

2

PolyProducer - Initial Prototyping What is the PolyProducer?

Once we had decided to pursue the idea of

transforming ‘candyfloss-like’ PET into packaging it

was clear that the first crucial stage would be to

work out how to produce the floss material.

Research into existing candyfloss machines

revealed that there are two basic components : a

perforated spinning container and a heat source.

This page details the first steps we took to produce

such a machine which shall henceforth be

referenced as the “PolyProducer”. It was decided

that we would produce our own machine because

existing candyfloss machines would not be able to

reach the 260°C melting temperature of PET , they

were very costly and we wished to redesign them

for an industrial context.

First Sketches

Heat gun used as

the heat source

Contains shredded PET

Electric drill used

to provide the

rotational motion Cable ties used to

attach to frame

Two steel bowls

welded together

Large hole for

shredded PET

Small holes to

allow extrusion of

PET Inserted into drill

Large enclosure

surrounds

everything

Vacuum formed

rounded base

Acrylic sheet

or cardboard

First Prototype

Tried pre-heating

bowl without

spinning but resulted

in one spot getting

too hot

Bowl welded slightly

off centre so

vibrations occurred

Observation window got

too hot and started

to deform (ABS)

A single heat gun was not

heating the PET sufficiently

Stable platform

for drill and heat

gun

Produced our first fibres! - This

proved that our method could

work and now just needed

improvement

Decided that cardboard

would be suitable for the

shield

Holes drilled in

bowl using a

milling machine

Thin fibres showed that

the hole sizing in the bowl

was correct

Sheet steel rolled and spot welded

rather than a second bowl

Addition of a lid

A lid was added

to retain heat

A thick acrylic viewing window was

used because temperatures were

increasing

Concrete blocks were

used to restrain vibrations

The additional heat

retention allowed the PET

to melt and form floss

Some floss melted

onto the heat gun

The floss had not cooled when it

struck the walls, so bonded into

layers

Air-cooled floss had the

properties we desired

Second Prototype

New larger enclosure to allow air-

cooling of floss Heat gun mounted above

for more direct heating

Vibrations broke the first

heat gun, so made a

separate frame

Fine fibres and no longer melting

together

Folded over to retain

more heat

Need larger

quantities

3

2

PolyProducer - Further Prototyping Parameter optimization

Once the PolyProducer was reliably producing floss,

it was time to optimise parameters. The diagram on

the right shows how the rotational velocity of the

pod affects the force exerted on the fibres.

Rotational velocity was easy to adjust using the

speed control on the drill. The heat gun only had

two settings and so heat was controlled by raising

and lowering the heat gun relative to the pod.

More holes

Initially, the steel sheet was only

added to prevent spillage. However,

it soon became apparent that the

molten PET was climbing up the

walls. Therefore we were able to

vastly increase the floss production

rate by adding 7 more rows of holes.

Heat gun stand

Relocating the heat gun prevents

the floss hitting it; increases the

temperature in the bowl; separates

it from vibrations and decreases the

start-up time. However, the stand

caught floss before it had fully air

cooled. This should be avoided in

the final product.

Speed Result

Too low No extrusion

Too high Waste of energy and

damage to fibres

Heat Result

Too low No extrusion

Too high Dangerous burning of

PET

Heat gun

adjustment

Regularly adjusting the heat gun

meant that it was not always

securely fastened. In one test, the

heat gun came loose and hit the

spinning pod. This broke the weld

at the bottom of the pod and

demonstrated the importance of

rigidity in the final design.

PET shredding

For the first tests we cut up

PET bottles by hand using

scissors. However, clearly

this would not scale up for

an industrial machine.

Therefore, we purchased a

garden shredder which

quickly tears through PET

bottles and reduces them to

chips.

Hole sizing

The hole size was originally set as the

smallest centre drill in the workshop

which could withstand drilling into

stainless steel (the bottom section).

There was concern that these holes

would be too large for fine fibres.

However, as the photo and sketch show,

what actually happens is that the PET

initially extrudes thickly but is then

pulled out into thin fibres by the

centrifugal force. This meant that

hole sizing was not a parameter

which needed changing.

Rows of holes added using the mill

Rotational velocity affects

force on PET

Much larger quantities of floss produced

Getting wrapped around the stand

Not air-cooled therefore bonds together

Proposed solution: suspend heat

gun from the outer casing.

Rotates to allow PET to be added

Heat gun very close to spinning pod Broken pod Dislodged heat gun

Initial extrusion is thick Sequence of floss formation

1. 2. 3.

4. 5. 6.

Further extrusion results in more force

Necking occurs Snapping releases floss

Garden shredder used for

PET

Shredded PET 4

5

PolyProducer - Final Iterations

Before adding the constraints of what could feasibly be made within budget, in the time frame

and in the IFM and CUED workshops, it was decided that we would use CAD to design what the

PolyProducer would ideally look like. This freedom from constraints allowed us to create the eye

-catching concept shown below. We were then able to adapt this to be feasible.

Issues with concept

The concept on the left was printed onto a large poster which acted as a visual aid and allowed us to discuss how we

would realistically manufacture the PolyPack machine. Each component was considered separately with regards to its

ease of manufacture and its functionality. The results of this discussion are detailed below.

This discussion ended in an agreement as to how to build the final product for the design show. CAD was used to dimension these ideas and

enable us to more carefully think about how all the parts fit together. The CAD is shown below.

Clear domed

lid to observe

floss making

Hopper for

feeding in

shredded PET

Side window to allow

observation of floss making

at production level

Tube with

suction to collect floss

PolyPacker

machine

(discussed later in

portfolio)

Floss

collection bin

800mm diameter to allow air cooling

Houses motor for spinning

pod

Mounting plate

bolted to

factory floor

The largest vacuum

former could not

accommodate the

800mm diameter

required for the

domed lid.

This method of adding PET

is not well suited to

precision placement in the

small, hot, spinning pod.

The indented profile would does not add functionality

and would be very difficult to make due to complex

rolling and welding.

Side window adds complications in manufacture

without offering much benefit because the lid will

be clear.

A vacuum in tube adds

additional complications

but is not necessary due

to other possible

methods of floss

collection.

Retains a clear (acrylic) section which

is both aesthetically interesting and

practical for observing

floss production

Hinges allow clear half to

lift for routine maintenance

Discovered that we could

laser engrave our logo onto

a painted surface

Looks-like concept

Lid Design

Funnel Design Heat gun is mounted within funnel to allow

PET to be added centrally

Bottom section

Heat gun fits in the tube

Base Assembly

Top plastic sheet for aesthetic continuity

Ventilation holes for the drill

Design for Manufacture

Plastic

casing is

bent using a

strip heater

Pod is

similar to

the

prototype

because it

worked well

Drill slots

firmly

between

pillars

Sides can be

removed for

maintenance

Top section is in two

halves to clamp the drill

in place

Final CAD before manufacture

6

PolyProducer - Final Design Purpose

Shown on this page is the pre-production prototype which we

have manufactured. The purpose of this prototype is to show that

it is possible to create a PolyProducer which is suitable for a

factory environment. This robust prototype not only looks like it

should be in a factory but also functions very effectively at

producing the PET floss material which is needed for our

moulding stage.

Brick platforms

Early prototypes used con-

crete blocks to weigh the base

down and prevent vibrations.

In the final design we used

the laser cutter to shape re-

cesses for bricks as this is a

much tidier and more efficient

way to weigh down the base.

Decoupling latching

The large steel shield is made of

two halves to make

transportation easier (otherwise

it would not fit through doors).

These halves are easily fastened

using toggle latches and two

pieces of steel. This decouples

positioning and fixing of the

steel shield.

Angled floor

The floor is angled and a

hole cut in the side of

one half of the steel

shield to aid collection

of the floss. The idea is

that once the floss has

cooled it will slide

down the angled floor

and out of the square

hole.

Base plate

It was decided that the steel

sheet should not sit directly on

the factory floor due to the

risk of corrosion and the fact

that factory floors are often

not flat. Instead a painted MDF

base with adjustable rubber

feet was added. Height increase

The shield was originally designed to be 800mm tall, however, it was decided to

increase this to 1m. This reduces the risk of the air within the shield overheating

and floss not air cooling before it hits the wall.

Frame Design

A table frame has been used to

support the drill. This is primarily

made from 45x45mm wooden

columns which are rigid and strong.

The drill housing is completely

separate from the steel shield to

reduce the length of force loops

and prevent vibrations in the heat

gun as we discovered that this

damages them.

Lid Design

The lid is not totally transparent due to limitations in the

size of acrylic sheet available to us.

7

PolyProducer - Exploded View

8

First Sketches Idea 1 Prototype

Sandwich maker

What is the PolyPacker?

In order to convert the floss material into

packaging we had to design a mould / forming

device. This was a larger unknown than the

PolyProducer, with very little existing technology

to inspire us. Two design ideas were generated

and the simplest, design idea 1, was taken forward

and tested. Its success led to more extensive

development which is detailed below.

PolyPacker - Initial Design & Prototyping Cool base keeps one side as

soft “floss”- two of these

sections would come

together to form

a package

Heated mould melts outer layer of

plastic, forming hard shell as

mould cools

Simple design would suit wide

range of shapes

of products

Design Idea 1

Pushed manually but

could be automated

Could include more

heated/moving parts

to reduce manufac-

turing steps

Design Idea 2 To increase pressure, heated plates

are pushed inwards to form 2 hard

sides. The part is then rotated and

Simple prototype

Overheating caused

discolouration

Smooth

surface finish

-Simply proved concept in

minimum time

-Tests carried out by applying

heat with a heat gun to melt the

plastic

Due to its simplicity, design

idea 1 was selected to be pro-

totyped .If successful, design

idea 2 would be dismissed

Test 1: heat from top

Plastic fell away from mould– would be

unable to have pattern/ dimensional

accuracy

Test 2: heat from base

Stuck firmly to base: need to consider

material and potential release agents

Shell and floss

remained well

connected

the process is repeated

Following tutor recommendations,

a toasted sandwich maker was

purchased as this replicated the

heated mould we were after

Thick, strong

shell formed

-No modifications to machine

-Insufficient heat to have any

effect on floss (limited to 140°C)

Test 2: 260°C for 2 minutes

Too hot: all floss melted into

hard layer

Demonstrated strength that

could be formed- very high

Thermal switch removed to allow

higher temperatures. All tests car-

ried out using temperature probe

to ensure safe limits were kept.

Closer to desired result:

reasonable shell thickness

Fibres well attached to shell

Test 3: 220°C for 2 minutes

Incomplete shell

due to insufficient

floss

Molten plastic from top

had dropped down

causing damage—from

now on only one side of

mould will be heated

Clear pattern with

good finish

This was sufficient to prove the

viability of the design. In order to

avoid wasting time optimising

parameters for a design we would not

be using, we progressed to producing

our own mould with which testing

and optimisation could be carried out.

Test 1: Standard setting

Existing circuit

Both easy to

remove due to non-

stick coating

9

This gave a thin film as the outer shell ,

to which the fibres were still attached.

The flash was substantial and could be

used for joining 2 halves. The surface

finish was excellent and milling marks

could be seen (although not visible in

photo)

PolyPacker– Prototyping PolyPacker– Custom mould 1

-A mould milled from aluminium was

inserted into the sandwich maker

-Size was based on the latest iPhone

dimensions

-Corner radiuses were based on avail-

able tools and depth was constrained

by sandwich maker dimensions

-Milling marks were left to test wheth-

er these could be seen after moulding

Test 1: 260°C for 30 seconds

Test 2: 230°C for 2 minutes

Test 3: 230°C for 2 minutes with weight (half mould)

Far too hot: in the fibres instantly

became molten and burned. This

was extremely hard to remove and

left staining and scratches on the

mould

-Weight was used to apply more pressure to base. This resulted in a thicker

shell but also gave a deep recess (could be exploited for later designs).

-External discolouration was due to staining of the mould from test 1.

Mould release

“Fry-light” Cooking

spray

“Buffalo” silicone free lubricant

“Rocol” mould release spray +270°C

All tests experienced issues with the material stick-

ing to the mould. This issue was exaggerated with

the thicker shells. Parameters included tempera-

ture of removal (whilst still above Tg), mould de-

sign and the application of lubricants (discussed)

A low cost and easy to source option. This

seemed to make removal slightly easier

but the majority of it evaporated at the

temperatures required so was not a suita-

ble solution

Used by

the department for vacuum former moulds, this is

ideal for plastic removal. This made removal notice-

ably easier but at temperatures approaching and

above 200°C there was sever discolouration which

went on to stain the mould and product

Severe mould dis-

colouration

Custom mould 2 Following tutor recommendations the

mould was redesigned. This mould was

smaller which would allow more testing

with the material available. The shape was

much more contoured which we hoped

would offer multiple benefits:

-Improved aesthetics

-Easier mould removal

-Improved solidification of mould walls

Test 1: 200°C for 2 minutes, 11g floss (high floss density for pressure)

Test 2: 220°C for 1 minute, 11g floss

Test 3: 240°C for 30 seconds, 11g floss

This only set in some sections but held the shape of the mould well. There was

discolouration due to release spray but generally, surface finish was good

CAD of moulded shape

Designed for high temperature

moulding, this spray was the most

expensive option (£19.89).

However, it let the product be

removed easily with no

discolouration. This was used from

test 4 in mould 2 onwards (see next

page)

Temperature still too low. The flash could not be removed due to insufficient

release spray around the mould– will be applied in future

This temperature was far too high. The plastic instantly melted (similar, but not

as extreme, as mould 1 test 1). A temperature between 220°C and 240°C must

therefore be used

Cont. on next page

10

PolyPacker– Further Testing Custom mould 2 Cont. Test 4: 230°C for 1 minute, 11g floss

Test 5: 230°C for 1 minute, 16g floss, Rocol mould

The Rocol mould release allowed easy removal with no discolouration. The shell

formed was sufficient to provide rigidity and was equal on base and walls. There

was slight colour variation, maybe due to differential temperatures in the mould.

The interior remained flossy and was well combined with the shell. Flash was

substantial and strong.

Failure to remove packag-

ing

This could not be removed from the mould due to

insufficient mould spray. However, a shell could be

seen in the mould. The shards that could be re-

moved showed imprints from the milling marks–

showing a high standard of surface finish. The floss

had compressed to leave a cavity so more will be

used in future.

Joining moulded halves

Initial Idea: Hot Plate Welding

Flash removal: Scissors Flash removal: Hot wire

Hot Plate Weld– Initial Test

Logo imprinting The Vision

Moulded logo

Mould 1 was repurposed and CAM was

used to mill an apple logo into the base

(depth 1mm, height 60mm)

Each mould could only make one half of the packaging. Once these were

made we needed to join 2 together to make a full parcel.

Standard hot plate welding technique. Should work but may result in floss

melting inside so must be tested. (Product must also be inserted between steps

2 and 3) The Mould

-Completed at 250°C using existing PolyPacker machine, with flat plate inserted

-Where flash was present, join was strong and took only a few seconds to set

-Floss did not melt, retaining internal properties

Flash

Cut edge Cut edge

-Brittle material snapped during cut

-Rough finish achieved

- Simple, low energy process

-Material fused after wire– had to be

pulled apart during process

-Additional melting aided hot weld

bond

Test 6: 230°C for 90 seconds, 16g floss, Rocol mould release

Increased time at temp lead to floss compacting more. The interior was more

brittle and cavities appeared on the

wall.

Resolution very good with high quality

surface finish. Occasional air holes,

believed to be due to excessive

temperatures

11

PolyPacker– Final Design

Control unit

Aesthetics

Grip forks

Ejector pins

Sliding plate: SMED

In basic model this offers on and

off functions. Additionally ,

there is temperature

control, as well as a live

temperature readout to

ensure parameters are

acceptable.

Grip forks hold floss in place on top plate, allowing them

all to be lowered into moulds at the same time. This also

ensures floss is always placed centrally in mould.

Tested in real life with secure results.

8 mould halves were

selected as a balance

between size of

machine and high rate

of production. In reality

may be balanced based

on mould size and floss

production rate.

-Colours chosen to convey brand and fit

with existing PolyProducer aesthetic

-Overall form is functional to fit

industrial setting

- Kept plain to allow focus on control

features

Top plate can be slid in and out to allow floss to be loaded

onto forks before insertion into mould. This allows floss

to be inserted swiftly, reducing cooling and labour

required. Multiple plates would be supplied with each

PolyPacker.

These rise automatically when lid

is opened to help push packaging

out, allowing it to be lifted on

grip forks. Imprint will be seen so

tolerance must be very tight .

Mould cut-through

-A slight recess at top of mould

contains flash in useful area

-Curved walls give consistent wall

finish

Our existing design was sufficient to produce simple

packaging, but changes would need to be made for an

industrial setting. The second generation of machine was

designed with this in mind: improving production rate and

reducing labour time. Details of this design are shown below:

Introduction

Mould quantity

11

Product Analysis Product Analysis

PolyProducer

Manufacturing

Part Count: 186

Time to assemble (hours): 1.5

Cost of parts (£): 100

Use

Time to heat up (minutes): 15

Output (g/minute): 2

PolyPacker

Manufacturing

Part Count: 18

Time to assemble (hours): 0.25

Cost of parts (£): 30

Use

Time to heat up (minutes): 30

Time to mould (minutes): 7

Statistics for manufactured machines The statistics on the left relate

to the pre-production

prototypes which have been

created for the design show.

These clearly need more

refinement before being leased

as a finished product, which is

why the PolyPack machine will

spend a full year being

developed before releasing it to

our partners. Below is a brief

introduction to the types of

changes which we would be

looking to make in those 12

months.

Alterations for commercial production PolyPacker

The existing PolyPacker which

we have produced is functional

but could be improved to better

meet industry demands.

PolyProducer

The PolyProducer which we

manufactured is functional and

has an aesthetic which would be

suitable for a factory. However,

due to our production quantity

only being one and being

constrained to a budget, there

were some features which could

not be incorporated (see

annotations).

Design for assembly

Jigs would be made to aid all welding and

assembly steps. For

example this

magnetic welding jig

for holding the floor

at 20°.

Currently many

components are held

on using bolts. This is

because bolts are easily

adjustable. However,

once the design is

finalised these can be replaced by welds. This

reduces the number of components.

More reliable, less power

intensive motor used instead of

a drill. For example:

TEC Electric

Motor

0.33HP Foot

Mount

1380rpm—

£76.13

Heating elements encompassed in the spinning

pod much like in a candyfloss machine. This

gives more efficient heat transfer than a heat

gun.

Bolt to factory floor instead of

using bricks

Automated transport from

producer to packer

More intelligent control of

temperatures, pressures and

times

Steel and

plastic used

instead of

wood and

MDF because

they are more

durable

Use steel for

opaque side

of lid due to

durability

Automated floss insertion

to reduce labour required

Treated mould surface to

eliminate need for release

spray

12

13

Packaging Analysis Shell Properties -Latest iterations had a shell thickness (avg) of 1.13mm

-Vickers hardness testing showed shell HV=19.5. This

could be approximated for tensile strength Ϭ=65kg/mm2

(=HV/0.3) .

- PET offers tensile strength of 55-75 which offers room

for improvement, potentially through parameter optimi-

sation

-Dimensions are currently constrained by

the feasibility of producing sufficient floss.

- Dimensions currently proven to be feasi-

ble are shown

-This is sufficient for high end items such

as jewellery and perfume, but more work

is needed for larger items such as phones

Aesthetics

-Colour is beige and mottled. We believe this may be due

to overheating in the polyproduction process.

-This could be improved by changing parameters (during

both processes)

-This could be hidden by using a coloured source material

Interior

-During final tests the interior remained flossy.

The quality of this is directly related to the quality

of floss used

-But offered a protective, adaptable and

aesthetically pleasing interior

Embossed Features -Apple logo proved that features, even of small

size ,(height 1mm) were possible, with good

definition and surface finish

Joining and Opening: Current Method

-Currently uses hot wire methods but unsuited to high volume

production.

-Where the flash is able to meet the join is strong: sufficient

material must be used to provide sufficient flash and parameters

must ensure it is flat .

-Gives a joint which is plane of weakness: could be used for

opening but also could cause failure during transport.

Feasible Dimensions

Joining and Opening: Future Vision

Weight Weight = 32g = 3 plastic bottles

-Gap in hot plate results in 2mm opening which can be levered/

cut open by consumer using conventional letter opener

-Suction end-effector removes package (which is now joined) once

hot plate is removed

-Hot wire end-effector removes excess flash

-Highly automated system reduces labour required and increases

repeatability

gap in

hot plate

Presentation Drawing Presentation Drawing

Integrated, Sustainable, Customisable, Packaging Solutions