Reverse Engineering: Kitchen Smith Toaster

Objective

Take apart the Toaster. Document the Disassembly.
Learn how the Assembly works in terms of the interaction of parts with each other and fastening methodology.
3D Model all the parts using SolidWorks. In this case, 23 unique parts and 100+ total parts!!!!
Produce 2D Engineering Drawings with proper Geometric Dimensioning and Tolerancing per ASME 14.5Y standards, with proper Bill of Materials creation.
Understand and learn the Design for Manufacturability implementations in the various parts, understand the product designer's design intent, and decipher the design constraints to understand the designer's choices.

Produce the Assembly of the parts to recreate the actual product.
Learn and understand the material selection process with consideration of Ashby Charts, Economics, Manufacturability, and Scaled Production.
Identify the defects present in the manufactured part and recommend potential manufacturing improvements to address them.
Perform a Design for Assembly (DFA) analysis to obtain quantitative metrics and identify opportunities for optimizing the assembly process.
Suggest three improvements in DFM and DFA while optimizing for a reduction in final cost using the Order of Magnitude technique for Cost Estimation.
Document the entire process in a 45-page detailed report and present the findings in front of the class and the director of the design program at CU.

Report_Reverse Engineering of Kitchen Smith Toaster.pdf

You can see some of the media associated with the project below.

RE Project Presentation_Nayan, Carson, Naga, Sadhvik.pdf

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