X Ray Glasses Contents Log Of Revisions Introduction Product

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Write a comprehensive engineering report on the design and manufacturing process plan of X-ray glasses, including product description, specifications, manufacturing steps, process plans for parts and assembly, and relevant design considerations. The report should detail the materials used, manufacturing methods such as molding, cutting, joining, and finishing, and include relevant engineering drawings and documentation references.

Paper For Above instruction

The development of portable and functional X-ray glasses presents a unique intersection of innovative product design and efficient manufacturing processes. Such products appeal not only due to their novelty but also because of their potential applications in medical imaging, security screening, and educational demonstrations. An in-depth understanding of the design, materials, manufacturing techniques, and process planning is essential for producing high-quality, reliable X-ray glasses while optimizing costs and throughput.

Product Description and Specifications

The X-ray glasses consist of three primary components: the frame, lenses, and decorative feathers, assembled to produce an illusion of X-ray vision. The product aims to be lightweight, durable, and aesthetically appealing to function effectively as a novelty item. The frame is designed to fit comfortably on the face, with the lenses providing the "X-ray" illusion, and the feathers adding a decorative touch.

The frame is fabricated from plastics that are heat-stable, easily colored, and durable. The lenses are constructed from cardboard, selected for its ease of processing, surface adherence, and bending resistance. Decorative feathers are attached for visual appeal, combined with printed ink coatings to enhance the illusion. Critical specifications include dimensions of the lenses (approximately 2.620 inches by 1.350 inches), frame width (about 6.266 inches), distant holes for assembly, and the overall aesthetic integration of components.

Materials Selection

For the framework, thermoplastics such as polypropylene are ideal due to their ease of molding, chemical resistance, and colorability. Additives like antioxidants, stabilizers, and fiberglass reinforcement enhance durability and manufacturing performance. The cardboard used for lenses must have a fine, compact structure with a surface conducive to adhesion of painting and ink, with thickness optimized to resist bending and deforming during assembly. Feathers comprise optical silk or similar synthetic fibers to simulate a realistic look, glued securely to the frame and lenses.

Manufacturing Process Plan

Frame Manufacturing

The process begins with plastic pellet melting through a high-temperature extrusion or injection molding technique. Injection molding is preferred for detailed, repeatable shapes needed for the frame. This involves heating the plastic pellets to approximately 300°F (149°C), then injecting the molten plastic into precisely machined molds using high-pressure machines to form the frames. Molds are designed with cores and cavities that match the specified geometry, including areas for hinge placement, nose pads, and decorative openings. After solidification, the molded frames are ejected, then undergo finishing processes such as trimming and surface smoothing with abrasive machines or grinders to remove flash and rough edges, resulting in a polished surface.

Lenses Manufacturing

To produce the cardboard lenses, sheets are cut into precise shapes using stamping or blanking operations. The sheets are first coated with ink via printing presses, creating visual spiral patterns that simulate X-ray images. The blanking machines use metal cookie cutters aligned with the desired lens shape to cut the cardboard into matching pairs. The lenses are then conditioned by folding or layering to produce a double-layered structure, enhancing rigidity and visual depth. After assembly, they are perforated with holes at predetermined locations using punchers, and glued with feathers to enhance the illusion of X-ray translucency.

Assembly Process

The assembly involves several steps: attaching the lenses to the frame via internal grooves designed to snap-fit or be glued, crocheting the decorative feathers onto the sides of the frame with appropriate adhesives, and bolting components like the bridge and temple arms with steel bolts. Use of bolts ensures ease of assembly and disassembly, facilitating repairs or modifications. The final product undergoes inspection, ensuring the lenses are securely fitted, the decorative feathers are well attached, and the overall aesthetic is met according to specifications.

Engineering Drawings and Documentation

All parts must be documented through orthographic and isometric drawings, showing dimensions, tolerances, assembly notes, and material specifications. For instance, the frame drawing includes views of the front, side, and section cuts identifying hinge locations, screw holes, and contours. The lenses drawing highlights dimensions, the spiral pattern, and hole placements. A BOM (Bill of Materials) accompanies drawings, detailing component quantities, materials, and supplier information where applicable.

Design Considerations and Quality Assurance

The design emphasizes simplicity to reduce manufacturing costs while maintaining product integrity under typical usage conditions. Materials selected are resistant to environmental factors like humidity and temperature fluctuations. The manufacturing processes are chosen for their repeatability, cost-efficiency, and tool availability. Quality assurance measures include inspection templates, dimensional checks, and visual reviews of the final assembly to ensure product specifications are met.

Conclusion

The manufacturing process plan for the X-ray glasses is a systematic approach combining plastics molding, cardboard processing, and assembly techniques. By carefully selecting materials and processes aligned with design criteria, the product can be manufactured reliably and efficiently. This process plan demonstrates the importance of integrating design considerations early in manufacturing planning, ensuring a high-quality, consumer-ready product that meets both aesthetic and functional expectations.

References

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