COIN HOLDER FOR INDIAN

MARKET
Design Technology Internal Assessment SL

SESSION: MAY 2021

PAGE COUNT: 21
Word count: 2064
Table of Contents
Description of the problem..........................................................................................................................................2
Design Brief................................................................................................................................................................... 5
Rough Sketches...........................................................................................................................................................7
Conceptual Modelling (CAD modelling).....................................................................................................................8
Design 1..................................................................................................................................................................... 8
Design 2..................................................................................................................................................................... 9
Design 3................................................................................................................................................................... 10
Design 4................................................................................................................................................................... 11
Evaluation against Design Specifications...............................................................................................................12
Final Design................................................................................................................................................................ 12
Final Design Chosen..................................................................................................................................................13
Changes made to final design (Fig.6)..................................................................................................................14
Component List...........................................................................................................................................................15
Material Selection...................................................................................................................................................15
Feasibility of Manufacturing Processes...............................................................................................................16
Joining processes...................................................................................................................................................16
Final Detailed Rendering of Product........................................................................................................................17
Bill of Materials............................................................................................................................................................21
Construction Plan.......................................................................................................................................................21

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Description of the problem
Men use wallets to carry personal belongings such as paper notes, currency coins, credit cards and other
personal identification documents. However, organising coins in a wallet has been a major problem for men
who carry wallet. Men are reluctant to carrying coins in their wallet and whenever they receive coins as
change, they either return it or donate it in charity boxes. Overlapping of coins in the wallet causes the
wallet to look bulky and makes it difficult to carry. The coins damage other belongings kept in the wallet and
the wallet itself. A lot of men in India carry their wallet in the back pocket of their trouser which is harmful for
their health. Keeping coins in the wallet only makes it worse. 1 The coins also make rattling sounds
sometimes when kept in a wallet. Even though a lot of wallets have a separate pocket for coins, some don’t
in which the fear of falling coins persists. Coin management is a major issue not only in India, but
throughout the world. Hence, a product that effectively manages coins and solves all these problems must
be developed.
Pictures of the problem

Figure 1 Damage to the wallet and other belongings.

Figure 2 Overlapping of coins in wallet.

1
Green, Dennis. “Why You Should Never Keep Your Wallet in Your Back Pocket.” Business Insider, 25 Apr.
2016, www.businessinsider.in/Why-you-should-never-keep-your-wallet-in-your-back-pocket/articleshow/
51983826.cms.
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 Figure 3 Discussing problems with users.

Figure 4 Discussing problems with users.

Figure 5 Primary data recorded.

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Figure 4 Number of coins carried by men recorded.

Figure 5 Comparison to existing product.2

2
COIN SORTER WALLET. “Coin Purse Wallet With Coin Sorter.” Amazon, 2020, www.amazon.com/Coin-
Purse-Wallet-Sorter-Change/dp/B01BBJ95LS.
4
Design Brief
The coin holder needs to fit average Indian wallets and should be able to efficiently hold at least 5-6 Indian
currency coins. The holder must prevent the rattling, falling and overlapping of coins. Should also prevent
the coins from damaging the wallet and other personal belongings. The holder must be flat and not be too
thick as it will nullify the initial objective of preventing the wallet from being bulky. It should be easy to use
as it will be used on a daily basis. The holder must be durable enough to withstand pressure on wallet. The
holder must sort the coins in 3 partitions as the dimensions of each coin is different.
This project could be constrained due to the outburst of Coronavirus and nationwide lockdown. However, to
ensure thorough feedback, online video conferencing and other such mediums shall be used.
If the product can efficiently manage coins in a wallet, it shall be considered a success. The project is
feasible as there are multiple and easy ways to manufacture it in my school. However, certain machines
could cause problems to students nearby due to their sound or by-products.
Design Specifications

Specifications Justification
Must prevent overlapping of Overlapping of coins causes the
coins. wallet to become bulky. Also,
men usually keep their wallet in
the back pocket of their trousers
and overlapped coins make it
difficult to sit on. (Fig. 2)
Must prevent coins from Coins are made of ferritic
damaging wallet and other stainless steel.3 This makes other
belongings. belongings and the wallet prone
to wear and tear when pressure
Function is applied on the wallet. (Fig.1)
Must prevent rattling of coins to a Coins create rattling sounds
desirable level. when wallet is shaken which is
undesirable. (Fig.4)
Must prevent coins from falling The wallet might be overturned
out. upon which the coins should not
fall out. (Fig.4)
Must sort coins according to their Indian coins have different
dimensions. dimensions. (Fig.5)
Coin holder must fit the wallet The coin holder should be the
size of the wallet to make it
Dimensions easier to carry. (Fig.5)
Should easily hold Indian coins The coin holder must be able to
hold Indian coins.
Must fit wallet size. Men will carry the product in their
wallets.
Should be simple and feasible. The product is of daily use and
Performance hence, has to be practical to use.
Must perform the same task Putting and taking out coins is a
repeatedly. recurring and imminent process.
Should not be made of Could damage the wallet and
chemically hazardous user.
Safety substances.
Should have essentially flat To prevent damage to wallet and
surface. user in case the user sits on the
wallet or keeps the wallet in his
back pocket.

3
Reserve Bank of India - Coins, www.rbi.org.in/scripts/ic_coins_5.aspx.
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 Should not have tacky colours. The target audience is teenagers
and adults who prefer classic
Aesthetics colours.
Product should not look cheap. The material used to make the
holder has to be of good quality.
Should at least be able to According to the survey
Size accommodate 5-6 coins, notes conducted, men usually carry 5-6
and other belongings. coins in their wallet (Fig.6).
Has to be tough and strong but The coin holder could break
Durability not brittle inside the pocket if it’s not strong
enough.
Has to be flexible Being flexible, the product will not
break easily even in extreme
pressure conditions.
The product is not meant for At times, can be exposed to un-
extreme condition; however, favouring weather conditions.
should be able to survive when
exposed to extreme conditions.
Environment Production of the product should Amidst the increasing global
not harm the environment. warming and pollution, the
production should be
environmental.
Should be waterproof and easy Wallets are of daily use and
to clean. hence, product is subject to a lot
dust and dirt. Thereby, the
Materials product should be easy to clean.
Must be tough. The wallet is of daily use and
hence, should handle daily wear
and tear.
Cost Must be cheap. As Indian men prefer buying
cheap wallets.
Product should be suitable for Mostly wallets are used by
ages 13+. teenagers and adults. However,
User the product can also be used by
other age groups if want to.

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Rough Sketches

Rough sketches of the coin holder:

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Conceptual Modelling (CAD modelling)
Design 1

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Design 2

9
Design 3

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Design 4

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Evaluation against Design Specifications
Specification point (Maximum 5 points for each Design 1 Design 2 Design 3 Design 4
criteria)
Target audience: Men who use wallet. 5 5 5 5
Target market: Men’s wallet market. 5 5 5 5
Holds at least 6 Indian currency coins (Fig.4) 4 4 3 3
Prevents overlapping of coins 5 5 5 5
Prevents damage to wallet and other belongings 5 5 3 5
Prevents rattling of coins 5 5 5 5
Prevents coins from falling out 4 4 5 3
Size: Fits the wallet 5 5 5 5
Ease and feasibility of use 5 3 4 5
Durability 4 5 5 3
Aesthetics 5 5 5 3
Comparison with existing products 5 5 5 5
Total (Maximum 60 points) 57 56 55 52

Figure 6 Testing and brainstorming designs with users.

Final Design
After testing and brainstorming the designs with a lot of people (Fig.6) (including women to get an extra
perspective) and pondering upon them myself, I now have a better understanding of all the 4 designs.
Deciding upon the final design was difficult as all the designs were desirable to the audience. However,
design 1 was selected after great discussion as it had the best score (57) and by making a little change to
the design, the product satisfies a much larger audience.
Design 1 can hold 9 Indian currency coins, is moderately thin, prevents rattling and falling of coins, fits the
wallet, is acceptably durable and repeated use is easy as the open spaces make taking out coins very
easy. Being acceptably flat atop, it also prevents damage to wallet and other personal belongings in wallet.
The design fills all the shortcomings of other designs such as feasibility of use, damage to the wallet and
falling out of coins. Hence, design 1 was chosen as it best suffices the Design Specifications.

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Final Design Chosen

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Changes made to final design (Fig.6)

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Component List
No. Component Material Manufacturing Image
Name process
1. Coin holder PLA FDM 3D Print

2. Protrusion Rubber CNC router/

Laser cutting

Material Selection
Variable (out of 5) Polylactic acid (PLA) Acrylonitrile Butadiene PETG
Styrene (ABS)
Mechanical Properties Durable and tough but Strong, tough, durable, Durable, strong, more
not as tough as ABS, brittle flexible than PLA or
could shrink after 3D (3) ABS, scratches easily
printing and can absorb
(4) moisture
(4)
Physical Properties Light weight Light weight Light weight
(5) (4) (5)
Cost ₹1,617 for 1kg, ₹1,617 for 1kg, ₹2568 for 1kg
(5) (5) (4)
Availability Readily available in Readily available in Readily available in
India India India
(5) (5) (5)
Environment Biodegradable Non-biodegradable Biodegradable
(4) (2) (4)
Finish required Yes: can be treated with acetone to smoothen Yes: can be treated with
(4) ethyl acetate to
smoothen
(4)
Aesthetic Properties Printed with high Printed with different Printed with high
surface quality, different colours and matte finish surface quality, different
colours, glossy finish (4) colours, glossy finish
(5) (5)
Based on specifications Durable, tough, flexible Strong, tough but brittle Durable, strong, more
(4) (3) flexible
(5)
Total (40) 36 30 36

Through this table, the material for 3D printed component was decided.

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Feasibility of Manufacturing Processes
Variable (Out of 5) FDM 3D Printing Injection Moulding Hand/ Machine tools
Complexity Complex shapes on Complex shapes using Complex shapes are
XYZ axes moulds difficult to make
(5) (5) (3)
Cost High initial set-up cost High initial set-up cost Skilled labour can be
(3) (3) fairly expensive
(4)
Skill required High skill required to High skill required to Extremely high skills
create drawings create moulds required
(3) (3) (1)
Repeatability Can produce same Can produce same Difficult to make exactly
products once products once same products.
programmed programmed (2)
(5) (5)
Accuracy High High Low
(5) (5) (2)
Product finish Finishing required, is Light finishing required A lot of finishing is
however, easy (4) required
(4) (2)
Waste Low waste No waste Likely to produce waste
(4) (5) (3)
Materials Several types of plastic Several types of plastic Several types of plastic
(4) (4) (4)
Time Can take considerable Quick to produce once Takes long time to
time to print the product programmed produce product
(3) (4) (1)
Availability Available Not available Abundant tools available
(5) (0) (5)
Total (Out of 50) 41 37 27

Joining processes
Variable (Out of 5) Adhering Fusing Nuts and Bolts/screws
Accuracy Parts are adhered Parts are adhered Holes and marks will be
manually; thereby manually; thereby created by FDM printing
lowering accuracy lowering accuracy (5)
(3) (3)
Cost Inexpensive Tools required are fairly Inexpensive
(5) expensive (5)
(5)
Skill required Not much Skills to use fusing tools
Skills to mark and make
(4) (3) holes
(3)
Availability Readily available in Readily available in Readily available in
India India India
(5) (5) (5)
Suitability for chosen Suitable for permanently Cannot be used with Such small screws and
material joining rubber with rubber bolts will make the
PETG. (0) design highly intricate.
(5) (1)
Total (Out of 25) 22 16 19

Even though PLA and PETG both had a similar score (36), PETG was selected over PLA for 3D printing for
its more flexible mechanical property. The coin holder has to be flexible and strong at the same time to
prevent the product from breaking inside the wallet. PETG is easy to work with, has good aesthetic

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properties, is cheap, and has tough and flexible mechanical properties. Use of PETG has low-carbon
emissions which promises sustainable growth.
3D printing ensures precise and accurate production of the product which is a must considering the size of
the product. Slightest inaccuracy could cause coins to overlap and spoil the whole purpose. Once
programmed, 3D printing will produce same products each time. However, the products will need to be
treated with ethyl acetate for final finishing.
The protrusion component is very small in size and hence, needed to be CNC/ laser cut to ensure
precision. The component needed to be a little soft and frictional. Thereby it could be made of either silicon
or rubber. Silicon however, is expensive and hence, rubber was selected.
The 2 components can be adhered to each other using glue. Given the frictional nature of rubber, it should
properly stick to the coin holder without issues.

Final Detailed Rendering of Product

Figure 8 Left isometric view.

Figure 7 Right isometric view.

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Figure 9 Front view.

Figure 11 Right isometric view.

Figure 10 Right isometric view.

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 Figure 13 Back isometric view.

Figure 12 Back view.

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Figure 14 Top view.

Even though the designs are not to scale, they have been creaetd using CAD and can be shared with the
manufacturer.

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Bill of Materials
Component Material Size Quantity Finish Cost
Coin holder Polyethylene 30g per piece 1 Acetone 1g of PETG=
terephthalate ₹2.57
glycol (PETG) 30g of PETG=
₹77.1
Protrusion Rubber 1g per piece 6 Not required Less than ₹2
Total cost: Approximately ₹79.1

Construction Plan
Step Process Equipment Scheduling Quality Control Risk
Assessment
1. Creating the CAD software 2 hours Cross-checking No risk
3D digital file of all the
the coin holder. dimensions.
2. Printing the FDM 3D printer 6 hours Ensure the Emission of
coin holder in product does ultra-fine
FDM 3D not absorb particles/ hot
printer. moisture post extrusions and
printing. (PETG motors
absorbs
moisture)
3. Post Acetone 30 minutes The product Ethyl acetate
processing the should not be presents no
coin holder submerged for potential threat.
too long. However, could
affect eyes.
4. Protrusion CNC router/ 1 hour Equip the Fumes,
manufacture Laser cutter cutter with vapours,
fume exhaust particles etc.
system and could cause
filtration breathing
system. issues.

To prevent health hazards, use of personal protective equipment, eye/face protection, gloves, apron is
must.

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