Materials and Processes Report
Polymer Joints
DS-219
PDPM IIITDM Jabalpur
June 2, 2020
Group D
Partha S. Hukai (2018518)
Saurav Basumotari (2018526)
Mentor
Prof. Puneet Tandon
Professor of Mech. Engg; Professor of Design at PDPM IIITDM Jabalpur, India
SUMMARY
This report details a project undertaken by Design undergraduate students at the PDPM Indian
Institute of Information Technology, Design, and Manufacturing, Jabalpur as a part of the course
DS-219. The goal of the project and the course was to gain experience and knowledge on the
manufacturing processes that go behind producing a tangible product.
In this particular assignment, the original objective was for us to design and build a product that
compromises of polymer joints. Throughout the process, both the assignment requirements and
their corresponding specifications have been kept in mind. The process in its entirety is detailed
throughout this report, including methodology, procedures, analyses, and end results. A detailed
description, including plans and finalized design sketches of the components, is provided as well.
This report serves to document the entire process from the initial background research to final
recommendations for improvement to the final design. This report documents the entire design
process including the final manufacturing plan, the measures are taken to ensure that all
requirements of the assignment have been fulfilled and specifications have been validated, a
detailed description and analysis of every major manufacturing processes that are to be used to
produce the desired product, this also includes a description of the product and its features, and
finally, our recommendations concerning improving the final design and suggested future work.
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TABLE OF CONTENT
Summary…………………………………………………………………………………………..1
Abstract……………………………………………………………………………………....…....3
Introduction …………………………………………………………………………………....….3
Aim/objective………….………………………………………………………….……………….3
Research……….………………………………………………………………………….…...…..4
Ideation…………………....………………………………………………….………….......…....4
Concept…………..……………………………………….......…………………………………...4
Detailed design and planning………………..….……………………………………………....…4
Manufacturing……………………….……………………..………………………...…..……..5-6
Tools needed…………………………..………………………….…………………….....5
Materials ………………………………………………………………………....….…....5
Why Nylon?…………………..………………………………………………….………..5
Cutting the fabric…………………………………………………………….………....5-6
Sewing the fabric…………………………………….……………………....……..……..6
Fitting………………………….…..………………………………….…………………...6
Conclusion and Reference……………………………………….………………………………..6
Design sketches and plans……………………………………….………………………………..7
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DESIGNING A PRODUCT THAT CONSISTS OF POLYMER JOINTS
ABSTRACT
This report details the process of concept generation, designing, and manufacturing for a
product that consists of Polymer joints. The assignment was not done in the mechanical lab
workshop and rather we were given the entire semester to design and manufacture the
product or artifact. This required us to initially learn about polymer joints and its types,
the operations to perform to generate the desired joints, and the steps required to
efficiently and safely perform the same. We were initially required to both design and
manufacture the product but due to the current scenario, this requirement was changed to
us delivering the detailed design and manufacturing processes to be used to generate the
product. This report documents the very process including the measures taken to ensure
that all requirements and specifications of the assignments have been validated, and
recommendations concerning improving the product and suggested future work.
INTRODUCTION
Large molecules, called macromolecules, that are multiples of simpler chemical units called
monomers. Polymers make up many of the materials in living organisms, including, for example,
proteins, cellulose, and nucleic acids. Moreover, they constitute the basis of such minerals as
diamond, quartz, and feldspar and such man-made materials as concrete, glass, paper, plastics,
and rubbers.
Polymer joints are the kind of joints that consists of polymers as the main component to bond
two surfaces or objects together.
AIM/OBJECTIVE
The objective of this assignment was initially for us students to design and manufacture a
product that consists of polymer joints and gain insight into the materials, manufacturing
processes as well as designing a particular product according to requirements. Now however due
to circumstances, the aim of the assignment is to deliver detailed design and manufacturing plans
highlighting the materials and processes used for the same.
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RESEARCH
During this stage, we were still unsure about what we will end up designing and making. This
made use look up a lot of projects done previously that could be considered under polymer
joints. We started looking for various kinds of polymer joints and ended up shortlisting a few
that kind of joints that could be used in a product and is feasible to manufacture at a smaller
scale.
IDEATION
We played around will the shortlisted ideas that were PVC potato cannon, face shield, and utility
garment. We ideated further and came into a decision that we would design and make a utility
garment and the situation around the world also influenced our decision making since we wanted
to make something that serves a purpose.
CONCEPT
We looked around the possibility of designing various forms of garment/clothing trousers,
footwear, jackets, etc. we ended up deciding we would design a utility jacket that is weatherproof
and can keep the individual wearing it comfortable.
DETAIL DESIGN AND PLANNING
It is best to pre-plan our design concept so we can correct any mistakes on paper before we get to
the actual material and can't go back. We sketched out some design concepts on paper then, once
we have decided on something. We can let your imagination go wild or if we prefer to stay with
a more traditional design. For this particular jacket that we designed, We chose to go with a
futuristic techwear aesthetic with a lot of straps and pockets for utility.
Designing to manufacture a garment needs a different approach now that we have the initial
sketched ready we now move on to make the ‘pattern’. Patterns are the blueprint of the apparel
design. It is important to start with the best possible pattern, as any mistake made in this process
creates problems later down the production line. This is why we chose to work on an existing
open-source pattern as a foundation and build on top of it.
Designing and making of templates along with planning was done digitally on Adobe illustrator
with 1:1 measurement and scale.
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MANUFACTURING
Tools needed
Heat gun
Sewing machine
Scissors
Exacto Knife
Iron
Basic Parts and materials
Nylon Fabric
Nylon Thread
Why Select Nylon?
We decided to go for nylon as our polymer of choice because we are designing for outdoor and
utility applications. This is why our material needed to be strong enough to survive the harsh
environment of the outdoors and ‘Coated Nylon Oxford’ checked all the boxes.
● Good Elasticity – Nylon will stretch up to 33% of its length and still regain its original
shape. This is very important in heavy traffic areas where furniture may be dragged
across the carpet.
● Very Abrasion Resistant – It even surpasses wool. Many manufacturers offer to wear
guaranties.
● Static Resistant – Not its ancestry, but today’s fibers do very well.
● Heat Sets Well – When properly heat set, nylon retains its crimp, twist, and dye
extremely well.
● Good resiliency – Nylon can be crushed for long periods and still regain its original
shape.
● Non-Absorbent – Nylon dries quickly since it will absorb less than 8% of its weight in
H20.
● Mildew Resistant – Nylon provides no food source, but mildew can grow on it if another
food source is available. Notice the damage that can be done under an over watered
potted plant.
● Nylon responds very well to most professional cleaning methods and treatments.
CUTTING THE FABRIC
Now that we have our pattern/template ready we can move forward and cut the fabric
accordingly. We do this by creating hard templates that are usually made of cardboard or any
thick paper. After placing the templated on these we then cut the cardboard according to the
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pattern and this gives us our final template. We then use this to repeat the procedure on the fabric
using the new hard template. We are also careful we do not make any errors while cutting the
fabric as this cannot be undone. If done correctly we will end up with desired fabric patterns that
would later be made into a jacket.
SEWING THE FABRIC
After we have gathered cut our fabric we can start putting it all together by sewing it using nylon
thread which acts as our polymer joint. Sewing the fabric will take a relatively long time and we
are to be careful while performing this operation to keep errors to a minimum. While sewing we
use the technique of zig-zag stitch as for our purpose this kind of stitch was found to be the best.
After we have completed stitching and making the garment we can proceed to the next step.
FITTING
This is where we try on the jacket and test its fitting and make changes to it if necessary.
Otherwise, we will have our completed utility jacket ready for outdoor use.
CONCLUSION
The objective of this assignment was initially for us students to design and manufacture a
product that consists of polymer joints and gain insight into the materials, manufacturing
processes as well as designing a particular product according to requirements. Now however due
to circumstances, the aim of the assignment is to deliver detailed design and manufacturing plans
highlighting the materials and processes used for the same.
To that extent, it has to be concluded that the objective of the assignment has been successfully
achieved as the team was able to not only learn more about the process of garment
manufacturing, various types of polymer fabrics, types of stitching/joints but also deliver detailed
design plans for a product.
REFERENCE
https://www.youtube.com/
https://sewingiscool.com/strongest-hand-stitch-vs-strongest-stitch-on-sewing-machine/
https://en.wikipedia.org/wiki/Nylon
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