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Designing Prototypes

Use Calculus to Minimize the Production Cost for a Company


Introduction In the next few days, you will design and create a prototype of a container for the energy drink company LimitlessEnergy Inc. LimitlessEnergy has decided that they are spending way too much money on their current containers for their energy drinks. They contacted New Prairie and specifically asked that the calculus students help them with their new design! They would like you to design the most inexpensive container possible for one of their four energy drinks (Unbounded, Infinity, Absolute Max, and Limitless). Guidelines While LimitlessEnergy Inc. wants you to be creative and make the design your own, there are a few guidelines that you will need to follow: The can must be a cylindrical shape The volume of the can must be 3.5 in3 The material for the top and bottom costs $0.02 per in2 The material for the lateral face costs $0.01 per in2 Net of a cylinder
Top

Lateral Face

Requirements With your group, you will need to complete 5 tasks:


Bottom

1. Determine the dimensions and cost of the most cost effective container (you will need to show any method(s) that you used and all calculations). You will be turning in a page with your calculations. Present them in a clear and concise way. 2. Create a 3-dimensional model of the container using Google SketchUp. You will be turning in the printed version of the model. 3. Print a 3-dimensional prototype of your model using the 3D printer. 4. Design a label (to scale) for the container for one of the four energy drinks listed above. Attach your label to the container! 5. Present your model to the class. Each group will put on a presentation. Topics for discussion include, but are not limited to: a. Discuss the method chosen to solve b. Walk through the calculations c. Provide the final dimensions and cost d. Be creative! You are trying to sell your product to LimitlessEnergy Inc. Suggested Timeline 12/3: Brainstorm ways to determine the minimum cost. Start calculations. 12/4: Finalize calculations. Design 3D model using Google SketchUp. Design label. 12/5: Finalize the label and model. Print the 3D model. Prepare for presentations. 12/6: Presentations and final thoughts

Google SketchUp
Creating Hollow Cylinders
Steps 1. Open Google SketchUp. If there is a man standing on the axes, click on him and delete him (unless you want him to hang around). 2. Click on the circle tool.

3. Click once on the origin (where the green, red, and blue axes meet) and drag your mouse away from the origin. Type the radius of your cylinder (in inches) plus 0.05 inches and hit enter. For example, if the radius is 4 inches, you would click the origin, drag the mouse away from the origin, type 4.05, and hit enter. 4. Your circle will likely be very small to see. Click on CameraZoom Extents. This should zoom in on the circle. If you do not like the view, you can click on CameraZoom and manually zoom in and out.

5. Next, you will be extruding the circle upward to create a cylinder. Click on the Push/Pull icon click on the surface of the circle, drag your mouse upward, type the height of your cylinder (in inches) plus 0.05 inches, and hit enter. For example, if the height is 12 inches, click on the circle, drag the mouse upward, type 12.05, and hit enter. If you need to rotate your view, click on the rotate icon. 6. Next, click the offset button . This will create a thickness for the

material used for the container. Click on the top of the cylinder, drag the curser in towards the origin, type 0.05, and hit enter. You should now have an additional ring on the top of your cylinder. 7. You will now hollow out the cylinder. Click on the Push/Pull icon again. Click on the inner circle

and drag the cursor down towards the bottom of the cylinder. Type the height of your cylinder in inches and press enter. This should hollow out most of the cylinder.

8. Save your completed cylinder. Click FileSave As and choose a name and destination. 9. Now you need to convert your file to an STL file so that it will print on the 3D printer. Click the select tool and triple click your cylinder so that the entire solid is selected. Click FileExport STL. Save the file somewhere where you can find it. Keep the file name short (less than 8 characters) and type .stl at the end of the file name. 10. Email your STL file to akutch@npusc.k12.in.us when you are finished. The subject area should include all of the group members names.