In MCEN 4026, I worked with two others to analyze a deconstructed hair dryer. We reverse engineered one of the components, cast it, and analyzed defects. By designing black box, glass box, and fishbone diagrams we evaluated the manufacturability of the hair dryer and proposed optimized design solutions.

 

There were four phases to the project. The first phase consisted of disassembly of the selected mechanical part (my group chose a hair dryer), creating a flat lay and BOM, and making the diagrams. In phase two, we modeled the wall plug cover in SOLIDWORKS and created a mold to cast the part. Calculations were performed to determine system properties like the Reynolds number and velocities at different points. These calculations, which can be seen in this report, were used to optimize the casting system if it was redesigned.