problem

To design coating die for high precision ink coating.  Incorporate fluid mechanics calculated pressure cavity. Create usable design that eliminates cleaning and maintenance issues and is light weight.

process

Worked with direct labor to identify issues with current design. Spent time working with coating process to understand issues. Worked with fluid mechanics engineers to determine process for incorporating calculated cavities into die.

solution

Created light weight ribbed design (not shown) with alignment key pockets to eliminate binding from dual pin and hole alignment system. Created radius’d edges and finger holes to allow for easier separation.  Used SolidWorks to create table driven cavity for EDM process.