David Winters
Pod Holder
Third Year
3 Weeks
This brief was for a piece of packaging that could be used to hold and return Tassimo capsules/pods to the manufacturer to enable specialist recycling. The holder needed to be reusable, hold 8 pods and made from a singular injection moulded part.
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The focus of this project was designing a part that was fully ready and viable for mass injection mould manufacture [250000 unit initial run]. The design needed to fit the brand, and remain durable within both the transit and sterilisation of the product to enable reuse.
Stage 1: Ideation
Initial potential concept directions for the pod holder. My aim was to design a holder with as few sliding cores as possible to keep costs low, hence the use of bump-off features within some designs. Concept B was chosen for refinement, partially inspired by the Tassimo logo.
Stage 2: Refinement
Refinement consisted of working the idea up into a piece that could be moulded without any sliding cores, and still allow easy access for pod ingress/egress. Dimensions were finalised using 2D models, and the idea of using TPU was formed due to its flexibility. A grade was then found with favourable mechanical and moulding qualities [Lubrizol Estaloc 59600].
Stage 3: CAD Model & 3D Print
A fully accurate CAD model was produced of the refined idea [and 3D printed in a rigid PLA, to try and simulate real world use]. This would be used later on in analysis and presentation materials.
Stage 4: Mould Flow Analysis
Using the CAD model, a mould tool was created for the part including ejector pins and venting. This was based off some mould flow analysis being done of the part to ensure it was viable for injection-moulded production.
Stage 5: Presentation Boards
Final presentation materials of the pod holder using Keyshot renders. Some key design features are:
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Easy to sterilise, high tear resistance TPU material selected.
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Bump-off rings to support pods.
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Fits through all standard UK postbox openings.
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Stackable for countertop use.
Stage 6: Finite Element Analysis
FEA performed on the Tassimo Pod Holder to determine its durability. Drop tests, stacking/lifting of the holders and pod ingress/egress were simulated within Solidworks.
Results then helped to come up with design alterations which would improve the design further. [This FEA study was done after the project's conclusion for a different module].
Stage 7: Engineering Drawing
Fully dimensioned engineering drawing of the Tassimo Pod Holder, including detail views to enable tool manufacture from this sheet.