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Reverse Engineering of a Manual Coffee

Grinder

MCEN 5045 – Design for Manufacturability


3/6/2018
Instructor: Dan Riffell
Yousef Al-Weqayyan
Yimeng Liu
Eric Perkey
Zach Yearout
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Executive Summary
The report details the reverse engineering project of a Vomach Manual Coffee Grinder

and how the product’s design has come to be. This includes the design analysis of the

components from a manufacturing, assembly, and economic standpoint.

The purpose of reverse engineering is to gain an in-depth understanding of the product by

unraveling the creator’s design intent and hopefully improve the product with three potential

design changes. Therefore, the engineering team sought to understand the design of each

individual component, why they are in a specific manner, the reasoning behind the material

choice, and the current manufacture and assembly process of the coffee grinder. Once the team

disassembled the product, 3D modeled parts as well as engineering drawings were completed for

each part. After conducting DFA analysis on the product, the team categorized the product into

three sub-assemblies each consisting a potential design change. Three part reductions made lied

within the Upper Body and Grinder Assembly, the Handle, and the Collection Receptacle. The

design changes improved from a DFA perspective at the expense of increasing the

manufacturing cost. Fortunately, the overall cost was reduced by ​24%​.


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Table of Contents
Executive Summary 2

Design Problem and Objectives 8

Gantt Chart 8

Black Box Diagram 9

Fishbone Diagram 10

Product Decomposition 11

DFA Analysis 17

Functional Analysis/Redesign Opportunities 17


1. Upper Body and Grinder Assembly 17
2. Handle 19
3. Collection Receptacle 20
Error Proofing 22
Handling 22
Insertion 23
Secondary Operations 23

Material Analysis 24
Grinder Core - Ceramic 24
Top Lid Cover - Rubber 27
Handle - Brown Oak 30
Body - Stainless Steel 33
Threaded milled rod - Stainless Steel 36

Manufacturing Analysis 39
Coffee Grinder - Body 39
Coffee Grinder - Grinding Mechanism 42

Economic Analysis 44
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Assembled View 50

Professional, ethical, and safety considerations 51

Conclusion 52

References 54

Appendices 55
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Table of Figures
Figure 1: Gantt Chart…………………………………………………………………………...8
Figure 2: Black Box Diagram…………………………………………………………………...9
Figure 3: Fishbone Diagram…...………………………………………………………………10
Figure 4: Upper Body Diagram………………………………………………………………..18
Figure 5: Redesign of Upper Body…………………………………………………………….19
Figure 6: Handle Diagram……………………………………………………………………..19
Figure 7: Redesigned Handle…………………………………………………………………..20
Figure 8: Collection Receptacle Diagram……………………………………………………..21
Figure 9: Collection Receptacle Diagram……………………………………………………..21
Figure 10: Grinder Core…………………………………………………………..…………..24
Figure 11: Possible materials for the grinder with a line of best
fit to show which materials meet the max strength 1 …………………………...25
Figure 12: A plot of the average cost of different materials…………………………………26
Figure 13: A plot of wear rate vs hardness of different materials ………………………….26
Figure 14: Rubber Lid………………………………………………………………………….27
Figure 15: Possible materials for the rubber cover with a line of
best fit to show which materials meet the necessary max strength……………..28
Figure 16: A plot of the average cost of different materials…...…………………………….29
Figure 17: Handle Piece………………………………………………………………………...30
Figure 18: Possible materials for the handle with a line to show
which materials meet the max tension loading using……………………………31
Figure 19: A plot of the average cost of different materials……………..………………….32
Figure 20: Collection Receptacle (Body)………………………………………………………33
Figure 21: Possible materials for the body with a line of best fit for
materials that meet the max load for a cylinder under internal pressure……...34
Figure 22: A plot of the average cost of different materials………………..……………….35
Figure 23: Threaded Rod………………………………………………………………………35
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Figure 24: Possible materials for the threaded rod……………..…………………………...37


Figure 25: A plot of the average cost of different materials……..………………………….38
Figure 26: Possible shapes for different stock materials and desired shapes……………….39
Figure 27: Possible machined shapes for different processes………………………………..40
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Table of Tables
Table 1: Product Decomposition of Manual Coffee Grinder………………………………...11
Table 2: DFA metrics of Original Design………………………..…………………………...17
Table 3: DFA metrics comparison of Original and Redesign………………………………..22
Table 4: Process Rejection Chart…………………..…………..……………………………..41
Table 5: Process Decision Matrix…………………..…………..……………………………..41
Table 6: Grinding Mechanism Process Rejection Chart……………………………………..42
Table 7: Grinding Mechanism Process Decision Matrix……………………………………..43
Table 8: Unit Cost Comparison - Original…………..…………………..…………………...46
Table 9: Unit Cost Comparison - Redesign………………………………..………………….46
Table 10: OME cost of Original Design………………………………..……………………...47
Table 11: OME cost of Remodeled Design……..…………………………………………….47
Table 12: CustomPart.net Quote Estimate of Original……………………………………....48
Table 13: CustomPart.net Quote Estimate of Remodeled Design…………..……………….48
Table 14: Break-Even Analysis of 5,000 Units of the Original and Remodeled Design…....49
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Design Problem and Objectives


The team was tasked to choose a product and follow the process of reverse engineering
while following the general design guidelines for manufacturability. The team decided to study
the manual coffee grinder and ultimately optimize the product. The project was broken down
into three phases: reverse engineering, design analysis, and redesign. During the reverse
engineering phase, 3D models and 2D engineering drawings were created for each part to better
understand the design intent of the product. The team primary objective was to reduce the part
count of the product by first conducting a DFA analysis of the coffee grinder, then assessing the
suitable manufacture method as well as material selection with the intent of reducing the cost as
much as possible.

Gantt Chart
In order to complete the project on time while keeping events organized, a Gantt Chart
was used to update the team with deliverables. Time periods for each task were created during
the initial phase of the project and were updated each week. The chart was found to be especially
helpful with updating other team members with individual progress. Overall, the Gantt Chart
ensured the task was completed to the proper standards and at the proper time. The complete
Gantt chart can be seen below.

Figure 1: Gantt Chart


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Black Box Diagram


The start of the reverse engineering process began with identifying the purpose and
functionality of the product. The team found the design to be effective in its use with a simple
design. Two inputs, rotating the crank and inserting coffee beans, resulted in an output of ground
coffee (coffee powder.) The black box diagram below shows this process. The processes by
which the grinder uses inputs to result in an output is not necessary to understand initially, but
rather to consider consumer and engineering specifications through this initial evaluation of the
product. This was performed before disassembly of the product in order to consider inputs and
outputs as they were designed for the system. Below is the black box diagram for the Vomach
Manual Coffee Grinder, with inputs and outputs shown on the left and right sides of the box,
respectively.

Figure 2: Black Box Diagram


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Fishbone Diagram
The fishbone diagram breaks down the coffee grinder into its subassemblies and
individual components. As the main centered horizontal line illustrates, all sub-assemblies
connect to the threaded rod of the grinder. Each angled vertical line delineates a sub-assembly,
while the small horizontal lines that stem off of each subassembly represent an individual part.
By connecting each part this way, it is easy to understand how the coffee grinder is assembled on
a surface level. The full fishbone diagram can be found below.

Figure 3: Fishbone Diagram


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Product Decomposition
To better understand the product, the team documented the disassembly of the product
and the individual component during the process. It is essential to understand how the parts
interfere and mate with each other. The material and manufacturing process was also determined
during this process. While decomposing the product, the team to identified potential redesigns to
the product. The following table (​Table 1​) depicts the decomposition of the manual coffee
grinder. It should be noted that some of the parts were not able to be disassembled ​(Parts 1003,
1007, 1008, 1009, 1011, 1013, 1015, 1017, and 1019) due to the manufacturing method
implemented by the designer, therefore Solidwork models of these parts were illustrated:

Table 1: Product Decomposition of Manual Coffee Grinder

Product Decomposition
Design Organization:Coffee Inc. Date: 2/26/18
Product Decomposed:Vomach Manual Coffee Grinder
Description​ A stainless steel mechanical coffee grinder with an adjustable coarseness level
mechanism.

How it works: Pour coffee beans in the cavity. Use the handle and rotate counter clockwise to
grind the coffee beans. Adjust the gear in the threaded rod to adjust coarseness level. After
grinding the coffee, twist the upper body to open base and use the grinded coffee for your
beverage.
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Parts:
Part # Part Name # Req’d Material Mfg Process Image
1001      Grinder Cap 1 Stainless Steel Die Casting

1002      Coffee     1  Ceramic Die Casting


Grinder-Core

1003 Crank      1 Stainless Steel Die Casting

1004      U-connector      1 Stainless Steel Die Casting

1005      Rubber Cover      1 Rubber Injection


Mold

1006      Grinder Mid      1 Stainless Steel Die Casting


Body

1007     Handle       1 Oak Machining

1008      Coffee      1 Stainless Steel Die Casting


Grinder-Base

1009 Blade 1 Stainless Steel Die Casting

1010 Coffee 1 Stainless Steel Die Casting


Grinder-Upper

1011 O-ring 1 Stainless Steel Die Casting


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1012 Bolt connector 1 Stainless Steel Die Casting

1013 Inner Blade Piece 1 Ceramic Die Casting

1014 Coffee Grinder-Cover 1 Stainless Steel Die Casting

1015 Bottom Cap 1 Stainless Steel Die Casting

1016 Gear 1 Stainless Steel Die Casting

1017 Threaded Rod 1 Stainless Steel Cold forming


and
threading

1018 Nuts 2 Stainless Steel Cold forming


and
threading

1019 Semi-Tubular Rivet 1 Stainless Steel Standardized


Part

1020 Fastener 2 Stainless Steel Standardized


Part
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Disassembly:
Step # Procedure Part #s Image
removed
1 Remove Rubber Cover 1005

2 Untwist Coffee Grind Cover 1008, 1011,


1015

3 Remove Grinder Cap 1001

4 Remove Handle, Crank, Rivet, 1003, 1007,


assembly 1019

5 Remove U-connector 1004     


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6 Unscrew Nuts   1018  

7 Remove Fasteners     1020 

8 Remove Gear      1016

9 Remove Bolt Connector 1012

10 Take off Coffee Grinder- Upper 1010


Body

11 Take off Coffee Grinder- Mid Body 1006


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12 Take off Coffee Grinder- Cover 1014

13 Take off Coffee Grinder- Core 1002

Links and drawing files:​      

Team member: Yousef Al-Weqayyan Prepared by: Yousef Al-Weqayyan

Team member: Yimeng Liu Checked by:     Eric Perkey

Team member: Eric Perkey Approved by:     Eric Perkey

Team member: Zach Yearout


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DFA Analysis
Upon disassembling the product, the team immediately realized room for improvement in
the assembly process. Overall, the design has self aligning features such as the mating of the
coffee base to the coffee cover (Parts No. 1008 and 1014)​. The product has minimal chance of
error proofing with the exception of the center blade ​(Part No. 1009)​, this is because the part
has distinctive features on faces of the blade which may affect the performance of the grinding of
the beans if placed incorrectly. The coffee grinder core, bolt connector, coffee grinder upper and
mid body, as well as the coffee grinder cover ​(Parts No. 1002, 1012, 1010, 1006, and 1014)
have difficulty during insertion. This is because the holes on these parts should be aligned in
order to insert fasteners. The following table is the DFA analysis of the manual coffee grinder:

Table 2: DFA metrics of Original Design


Functional
Analysis / Error
DFA Redesign Proofin Secondary
Complexity Opportunity g Handling Insertion Operations
←Theo
r. Effy.
Design for Assembly 34.583232 52.2 78.3
Pract.
Metrics 93 % Effy.→ % 0.08 1.08 0.92 1.00

Functional Analysis/Redesign Opportunities


The main focus for the redesign of the coffee grinder is reducing the amount of parts
needed to assemble. Based on the results of the DFA analysis, the design has the possibility to
cost less in its assembly process. This may save the manufacturer money in the production
lifetime and will drive the market price down.
After a brief analysis of the original design, it was found that the product was already
made with design for assembly in mind. The threaded rod (Part No. 1017) holds a majority of
the pieces in place when assembled. Six pieces (plus one fastener) are placed directly to the rod,
most of them being tapped. The product has an overall simple design, yet the team found three
design changes to reduce the time or effort in assembly, ultimately reducing the DFA
complexity.

1. Upper Body and Grinder Assembly


Current Design Description
When fully assembled, the design of the coffee grinder separates into two assemblies: the
collecting receptacle and the coffee bean placement cup. Coffee grounds fall into a collector that
twists on to the upper portion of the grinder where the beans are held. The component that
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connects the two assemblies together is comprised of two parts ​(Part No. 1014 and Part No.
1006)​. The team could not definitively find a reason for the component being separate pieces.

Figure 4: Upper Body Diagram


The area where coffee beans are placed in is a cup-like shape which has a part ​(Part No.
1012) that fastens to the grinder core (Part No. 1002) ​and a twist on piece connecting the bottom
receptacle to the top. It has been concluded that fasteners were used so the user may disassemble
the parts and clean them individually. In addition, the grinder core is made of a different material
than the body.
Redesign
The two components made to twist the upper assembly to the bottom receptacle can be
created as one piece. A mold that creates these parts as one is sufficient. This is a simple solution
that reduces two parts to one in assembly.
The fasteners connect a total of five components together. To maximize the reduction of
parts, the fasteners can be disregarded if these five components were made into one complex
component. The grinder core is made of a different material than the other four components, so
the piece would have to be made of a material that can satisfy the toughness to prevent wear on
the sharp edges. The material should also have the ability to be lightweight and thin to keep
functionality of the outer wall.
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Figure 5: Redesign of Upper Body

2. Handle
Current Design Description
In the original design, the handle engages with the threaded rod by a square hole. And it
acts as a crank to grind the coffee beans. It is currently comprised of three pieces: the crank, grip,
and a rivet. The head piece does not spin when rotated. The head piece is made of wood, and
seems to be pure aesthetic.

Figure 6: Handle Diagram


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Redesign
Again, this assembly can be made into one piece. The head piece does not spin when
rotated, so having a piece that combines all three components does not change function. The
piece would be slightly more complex, but would be an advantage to make from a design for
assembly point of view. Below is the redesign for the handle:

Figure 7: Redesigned Handle


The crank piece, or lever arm, is kept while the head piece (acting as an aesthetic grip)
and rivet are removed. Seen in ​Figure 7​, ​the crank arm was bent twice to act as the grip located
at the end of the arm. This keeps the functionality of the piece while simplifying the overall part.
There are several benefits to do this part reduction. First, the redesigned part reduces the
material cost of the product. Second, the original grip is lathed, while for the redesigned part a
simple bending feature is easier to manufacture than the original grip, which will reduce the
production time and cost of the product.

3. Collection Receptacle
Current Design Description
The coffee grounds fall from the grinder to the collection receptacle. This assembly is
currently comprised of three components. The bottom cap and O-ring attach to the main body. At
first glance the team assumed these were one piece. The O-ring was assumed to be used for a
tighter fit, or to prevent coffee grounds from escaping the receptacle. The bottom cap could be a
separate piece for ease of cleaning.
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Figure 8: Collection Receptacle Diagram


Redesign
The combination of the three components listed above would decrease the part count
from three to one. This would increase the cost to manufacture, but would decrease the cost for
assembly. The bottom cap may be used for ease of cleaning, but this use can be sacrificed for
cost. The team believes the O-ring is not essential to the design, and therefore was ignored.

Figure 9: Collection Receptacle Diagram


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The team found that reducing the part count ultimately reduced the DFA metrics, while
maintaining an increase to both theoretical and practical efficiency. Implementing the previously
mentioned design changes reduced the complexity factor from 34.58 to 15.16​. The following
table depicts the comparison of the DFA metrics of the Original and Redesign of the manual
coffee grinder. The full DFA table can be found in the Appendix:

Table 3: DFA metrics comparison of Original and Redesign


Functional
Analysis /
DFA Redesign Error Secondary
Part Complexity Opportunity Proofing Handling Insertion Operations
←Theor
. Effy.
34.583232 52.2 Pract.
78.3
Original Design 93 % Effy.→ % 0.08 1.08 0.92 1.00
←Theor
. Effy.
15.165750 90.0 Pract.
100.
Redesign 89 % Effy.→ 0% 0.11 0.56 0.11 0.78

Error Proofing
The goal for error proofing is preventing errors in assembly. The lower the statistical
number, the better. As seen in Table 3, the error proofing in the coffee grinder shows to be in a
safe zone. Most of the parts are large or unique enough that misassembly can be prevented. The
designers created the product with disassembly in mind. The threaded rod ​(Part No. 1017)
allows for the grinding components to easily fasten to each other, and the parts are unique
enough to identify the order of assembly. The redesign did not better or worsen this category, as
the threaded parts were not changed. The error proofing shows that the grinder was designed
well enough to prevent any confusion during use.

Handling
Most of the handling issues were from the Upper Body and Grinder Assembly ​(Parts No.
1006, 1012, 1014) and the Collection Receptacle ​(Parts No. 1008, 1011, and 1015)​. The Upper
Body and Grinder Assembly consisted of individual components prone to nesting and had sharp
edges, while the collection receptacle only had sharp edges. When fully assembled, the coffee
grinder can be taken apart to access the coffee grounds. This movement is done by twisting the
bottom apparatus counter clockwise. Besides this functionality, the fasteners are the only other
piece that interact with other components. The two nuts that fasten the grinder core to the upper
body are relatively difficult to access. The space is tight and is hard to use any tools to tighten.
However, the bolt-nut interactions are most likely meant to be hand tight. The redesign
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eliminates the nuts and bolts and therefore prevents any handling issues. This design improves
the handling greatly from ​(1.08) to ​(0.56). This leaves one fastening component that connects the
entire grinding assembly together. This piece is essential for the grinder to change grinding
effectiveness (how fine the grounds are.) Without this fastening piece the grinder loses
functionality and therefore was not redesigned.

Insertion
The grinder core assembly must be attached to the upper body. This requires the user to
hold the upper body, grinder core, and fasteners in place while the nuts are tightened. This
operation relates to handling issues when accessing the nuts discussed in the handling section.
The assembly of the components do not require any additional tools. The parts are all hand held
and can be assembled with hand tight fits. The redesign reduces the number of interactions and
parts needed to be held to assemble the grinder.

Secondary Operations
Secondary operations include re-orienting the workspace or using an additional tool or
material to assemble parts correctly. The product itself is purely mechanical, and almost no
secondary operations are needed to assemble the parts. A wrench ​may be used to tighten the
bolts, but hand tight fits are sufficient enough for this product.
Based of the metrics, the redesign from a DFA perspective has been a success, with an
increase to both theoretical ​(90%)​ and practical ​(100%) ​ efficiencies to the product.
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Material Analysis
Grinder Core - Ceramic

Figure 10: Grinder Core


1. Translate Design Requirements:

Function:​ The grinder core grinds the coffee beans into powder with the inner blade. This
allows for the coffee to be used in brewing of coffee itself.

Material Index:​ For a cylindrical vessel with internal pressure, to maximize strength:
M ax Strength = σ f /ρ
For steel with ρ = 8.05 M g/m3 and σ = 350 M P a the max strength is 43.48 MPa/(Mg/m^3)
Constraints/Requirements:
● Cannot deform while grinding
● Must be wear resistant
● Must be food safe
● Must be able to make complex geometry
● Minimize cost
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2. Screen Using Material Indices

Figure 11: Possible materials for the grinder with a line of best fit to show which materials
meet the max strength 1
3. Screen Using Constraints:
Based upon the line of materials that meet the design requirements, it is possible to use
wood, ceramic, steel, or other metal alloys. All of these materials meet the necessary design
requirements for this component and could be used for different reasons.

4. Rank Using Objective:


For this component, despite meeting the necessary strength requirements wood will be a
bad choice due to the fact it could deform or break under loading. The main materials that could
be used for this component are metal alloys and ceramics. They all meet the necessary strength
requirements, but have drastically different reasons as to why the should or should not be used.
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5. Seek Supporting Info:

Figure 12: A plot of the average cost of different materials

Figure 13: A plot of wear rate vs hardness of different materials


For this component the cheapest choice is stainless steel. Possible materials like wood
have low price points but have material conditions that make them bad for this component.
Metal alloys like steel, aluminum, and titanium have drastically different price points and for this
reason, titanium should not be used. Between aluminum, steel and ceramic, ceramic has similar
price range with stainless steel, but has the lowest wear rate and the highest hardness.
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6. Final Material Choice:


Alumina was chosen due to its relative high hardness and low wear rate compared to
other materials with similar price range. Also, Alumina is food safe, and are already widely used
in making ceramic knives.

Top Lid Cover - Rubber

Figure 14: Rubber Lid


1. Translate Design Requirements:

Function: The top lid cover prevents the coffee beans from splitting while grinding.
Additionally while in storage the cover protects the grinder from collecting dust within the main
body.

Material Index:​ For a plate in bending the max strength is given as:
M ax Strength = E 1/3 /ρ
For rubber with ρ = 1.1 M g/m3 and E = 55.0 M P a the max strength is 3.457 MPa/(Mg/m^3)
Constraints/Requirements:
● Need to be soft and provides good sealing
● Must be wear resistant
● Must be food safe
● Must be able to make complex geometry
● Minimize cost
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2. Screen Using Material Indices

Figure 15: Possible materials for the rubber cover with a line of best fit to show which
materials meet the necessary max strength

3. Screen Using Constraints:


Based upon the materials that meet the necessary strength conditions for this component
the possible materials are foams, natural materials, metals and composites.From these materials
foams would not be a good choice as they do not have any form of stiffness to give the piece
support. Metal and composites are possible materials for this component and have higher than
the necessary strength for this component. Additionally, natural materials would work for this
piece and have the necessary strength requirements as well.

4. Rank Using Objective:


For this piece, natural materials provide the most versatility to make the component out
of different materials. Certain materials will have better properties from others within natural
materials and so it is best to choose one at a low cost and the necessary strength properties.
Metals would also work for this component, but would require more complex forming methods
to produce with more expensive tooling and thus are not as economically feasible as natural
materials for this component.
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5. Seek Supporting Info: (Research history of top ranked candidates)

Figure 16: A plot of the average cost of different materials


For this piece it is more feasible to make it out of natural materials such as butyl rubber
than metals like stainless steel or aluminum alloys. This is due to the fact that butyl rubber costs
far less than the cost per unit of metals and will allow for cheaper forming methods than metals
need.

6. Final Material Choice:


The final material selected for this piece was butyl rubber due to its relative inexpensive
cost compared to other materials with high sealing characteristics. Also, butyl rubber is food
safe, which is important for this component due to the fact that it will be used in food
preparation. Finally, it will be easy to mass produce multiple components reducing the overall
cost of this piece in the final assembly.
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Handle - Brown Oak

Figure 17: Handle Piece


1. Design Requirements

Function:​ Provide easy access to use rotational motion to grind coffee beans using the grinder
core. Additionally, be able to easily fit in the hand of the user.

Material Index: ​For a bar in tension the max strength is given as:
M ax Strength = σf /ρ
For oak with ρ = 0.72 M g/m3 and σ = 5.50 M P a the max strength is 7.62 MPa/(Mg/m^3)

Constraints/Requirements:
● Does not break under loading
● Easy to produce/cheap
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2. Screen using Constraints

Figure 18: Possible materials for the handle with a line to show which materials meet
the max tension loading using

3. Screen using Material Indices


Based upon the line of materials that meet the design requirements, the possible materials
that could be used for the handle consist of foam, hard polymers, and nickel alloys. Additionally,
forms of wood could be used for this material but are ranked above the necessary design
requirements.

4. Rank using Objective


For this design, foam would be to soft for the necessary requirements of using as a handle
and thus would not work for this application. Additionally, polymers and alloys would work well
for this application, along with wood which would be cheaper and provide more strength than is
required for this component.
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5. Seek supporting info

Figure 19: A plot of the average cost of different materials


For this component the best choices that meet the design requirements are ABS,
aluminum alloys, or wood. ABS is a plastic material that could easily be produced, but also has
dangerous fumes associated with it and thus would cost more to produce. Aluminum alloys are
cheaper than ABS and do not have dangerous fumes associated with them and thus would be
safer to work with. However, tooling and machining of aluminum alloy pieces requires more
specific equipment and thus would have a higher tooling and manufacturing cost associated with
it. The last option, wood, is cheaper than both of the other options at a cost of $ 2.00 per unit
weight and $ 0.18 per unit volume. This means that large volumes of wood can be purchased for
cheaper than ABS or aluminum alloys allowing for more pieces to be produced.
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6. Final material choice


The final material chosen for this piece should be wood. This is due to the fact it is above
the necessary design requirements for the piece as specified and additionally has the lowest cost
per volume of any of the materials that meet the design requirements. This will allow for more
pieces to be produced for cheaper and thus simplify the production of this part. Additionally,
wood has a low tooling and manufacturing cost and thus money will be saved as well in the
manufacturing of this part by not having to use expensive tools

Body - Stainless Steel

Figure 20: Collection Receptacle (Body)


1. Design Requirements

Function: Be able to hold all components of the coffee grinder structure. Additionally, support
the other components with a rigid body to allow for other components to be attached onto and
contain all coffee beans and grounds within the system.

Material Index: ​For a cylindrical vessel with internal pressure the max strength is:
M ax Strength = σf /ρ
For steel with ρ = 8.05 M g/m3 and σ = 350 M P a the max strength is 43.48 MPa/(Mg/m^3)
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Constraints/Requirements:
● Strong enough to support other components
● Rust resistant
● Easy to produce
● Easy to form

2. Screen using Constraints

Figure 21: Possible materials for the body with a line of best fit for materials that meet
the max load for a cylinder under internal pressure

3. Screen using Material Indices


Based upon the line of materials that meet the design requirements, the possible materials
that could be used for the body consist of wood, ceramics, alloys, and steel.

4. Rank using Objective


For this component, ceramics would not be a good chose due to the fact they are too
brittle for this application. Additionally, wood would meet all design requirements, but would
slowly deteriorate over time and thus is not a good choice either. Therefore for this component to
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provide the longest lifetime of the product and protect it from corrosion and rust it is best to use
either steel or some other form of metal alloy to protect the components and allow for the easiest
forming of the components.

5. Seek supporting info

Figure 22: A plot of the average cost of different materials


For this component either stainless steel or some form of alloy, like aluminum, should be
used. Stainless steel has higher weight, density, and strength properties compared to aluminum,
but additionally costs more. Aluminum is lighter and easier to machine along with costing less
per unit mass than steel but does not have the same strength properties. For this component it is
important to make sure that it is strong enough to support all other components along with being
rust resistant. It is possible to apply finished that will protect the material against rust, but will
add to the overall cost of the material as well. The one other main option is some form of carbon
steel which maintains the same properties as stainless steel but cost less than aluminum.

6. Final material choice


For this component, the body of the grinder, it is best to go with aluminum alloy as it
provides all necessary strength properties along with being easy to machine and costing less than
the alternative, steel. By using aluminum for this piece as well instead of steel it will be cheaper
to purchase the material, machine, and reduce the overall weight of the product. This matters for
distribution and shipping of the product to the consumer and thus reduces the costs of all aspects
of this components compared to using steel.
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Threaded milled rod - Stainless Steel

Figure 23: Threaded Rod


1. Design Requirements

Function: Allow for multiple different pieces to be attached onto the shaft and transfer rotational
motion from the handle to the grinder core. Additionally, it must fit different components with
different finished onto the central component.

Material Index: ​For a bar in tension the max strength is given as:
M ax Strength = σf /ρ
For steel with ρ = 8.05 M g/m3 and σ = 350 M P a the max strength is 43.48 MPa/(Mg/m^3) and
for a bar in torsion the max strength is given as:
M ax Strength = σ f2/3 /ρ
For steel with ρ = 8.05 M g/m3 and σ = 350 M P a the max strength is 6.17 MPa/(Mg/m^3)
Constraints/Requirements:
● Easy to form
● Easy to produce
● High strength
● Rust resistant
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2. Screen using Constraints

Figure 24: Possible materials for the threaded rod.


3. Screen using Material Indices
The red line shows the line of materials acceptable based on the max torsion load on the
road and the black line shows materials acceptable based on the max tension load. Based upon
the line of materials that meet the design requirements for both the strength and torsion load, the
possible materials that could be used for the threaded rod consist of ceramics, alloys, and steel.

4. Rank using Objective


For this component, ceramics would not work well, as they are far too brittle and would
break under the loading. Additionally, they would not work well at connecting the multiple
different components for this piece. Alloys and steel however, can be formed easily and would
provide the necessary strength to connect all pieces and not break under the loading conditions.
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5. Seek supporting info

Figure 25: A plot of the average cost of different materials


For this component, steel and alloys are the best options. Stainless steel is the most
expensive option, but provides the highest material properties of any option. Aluminum alloy is
lighter, but not as strong as stainless steel. However, between these two is carbon steel which is
heavier than aluminum, with stronger properties, but overall costs less per unit mass. While not
being as strong as stainless steel, it still has some of the same properties and can be finished so as
to protect it from rust.

6. Final material choice


For this component, it is best to go with carbon steel, which can be easily machined and
his higher strength properties than aluminum. While not as strong as stainless steel, it makes up
for this fact in the cost per unit mass making the overall cost of this piece much cheaper. While it
will be heavier than aluminum and cost more to machine, for the purpose of this component and
how it will be the central axis to the product overall with many interfaces to other parts, it is best
to go with the option of carbon steel and ensure the piece is well produced and does not fail
during the product life cycle, which could result in warranty of the product and loss of money to
the manufacturer.
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Manufacturing Analysis
For the manufacturing and assembly of this product there are multiple different methods
that can be used. Each method provides different capabilities on the process itself and allows for
different finishes and properties of the pieces produced. While some components are
standardized and could be bought off the shelf, most of the pieces need to be machined or
manufactured. For the primary parts to this product however, the body and grinder, they were put
through the process selection to determine what method would be most appropriate for the
manufacturing of these parts.

Coffee Grinder - Body


For the coffee grinder main body it was determined that this component was made out of
304 SS. While it is possible to make this component out of other metal alloys, it is important this
component meet the necessary material strength requirements.
The body’s shape was first characterized using the spatial complexity table to determine
the shape of these components. While some components do have a uniform shape, many had an
irregular or complex geometry to them and thus were all standardized as either F7 or T7 shapes.

Figure 26: Possible shapes for different stock materials and desired shapes
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From here, the possible processes that could produce this shape geometry were
scrutinized to determine which methods were feasible for the production of this part. Based upon
the geometry restrictions the possible methods determined were centrifugal casting, die casting,
investment casting, permanent mold, sand casting, powder injection molding, injection molding,
blanking, and deep drawing

2
Figure 27: Possible machined shapes for different processes
From the possible processes available to make this component, these processes were then
analyzed to determine their capability to produce this specific piece. Despite all methods being
able to produce parts of component it was important to find a method that could be standardized
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to be able to produce all pieces. This would overall reduce cost and need for more tooling to
produce other parts.
Table 4: Process Rejection Chart

Possible Process Rejection Reason for Rejection


Cannot make all complex shapes or
Centrifugal R would require secondary operations
Die Casting
Investment Casting
Permanent mold
Sand Casting
Powder Injection Untreated powder risks
Molding R contaminating food
Not possible to use necessary
Injection Molding R material
Blanking R Unable to make all necessary shapes
Drawing R Unable to make all necessary shapes

From the final available processes that meet all design requirements, they were
scrutinized based upon the specifics of the method to determine which method to use.
Table 5: Process Decision Matrix

Process Material Tooling


Process Cycle Time Flexibility Utilization Quality Cost Total
Die Casting 5 1 4 2 1 13
Investment Casting 2 4 4 4 3 17
Permanent mold 4 2 2 3 2 13
Sand Casting 2 5 2 2 1 12

For the final body pieces the best method to produce these pieces was chosen as die
casting. This method has very short cycling time of parts, and thus allows pieces to be produced
in a line process maximizing production time. It also has a small material cost reducing the cost
of raw materials needed for the part. While it does have high tooling cost and low process
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flexibility, for the mass production of parts this method is the best option. After the large initial
investment cost in tooling, parts will be able to be produced on a much faster scale at lower
costs, which in turn will provide a larger return to the manufacturer than other methods.

Coffee Grinder - Grinding Mechanism


For coffee grinder grinding mechanism, it was put through a similar process as the body
to determine which methods are best for production. The component was classified as being a T7
component with internal features classified as U7. This makes the part more complex to
manufacture as a single piece and not require secondary operations to finish the component.
Therefore, this piece had a restricted range of methods to manufacture it, only being able to be
made through powder injection molding, compression molding, conventional machining, sand
casting, and investment casting.

Table 6: Grinding Mechanism Process Rejection Chart

Possible Process Rejection Reason for Rejection


Untreated powder risks
Powder Methods R contaminating food
Compression
Molding
Conventional
machining
Sand Casting
Investment Casting

Based upon the possible processes available that meet the necessary requirements, these
methods were analyzed to determine which process provide the best conditions for this part. For
this component it was important it could be produced in a similar manner to the body to allow for
a similar production time and assembly process of all components.
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Table 7: Grinding Mechanism Process Decision Matrix

Process Material Tooling


Process Cycle Time Flexibility Utilization Quality Cost Total
Conventional
Machining 3 5 1 5 4 18
Sand Casting 2 5 2 2 1 12
Investment Casting 2 4 4 4 3 17
Compression
Molding 3 4 4 2 3 16

The final method chosen for this piece was sand casting, while not as fast as the die
casting method, it is the cheapest method to produce parts considerably. Additionally, it allows
for a high amount of customization of the part for possible different iterations of the component,
allowing for the piece to be made through many iterations and overall reduce the cost.
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Economic Analysis
The market is driven cost, therefore the team performed an extensive cost analysis to
determine the cost of the product before and after the redesign. Several cost estimates were made
(Unit cost, OME, quote estimates, and breakeven point) to assure the cost analysis was
justifiable.
Unit cost is an in depth cost analysis of the product. The calculations involves the
material cost C M , labor cost C L , tooling cost C T , equipment cost C E , and overhead cost.
C OH , where
3
Material Cost CM :

Labor Cost C L :

​Tooling Cost C T :
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Equipment Cost C E :

​Overhead Cost. C OH :

The parameters above were then summed up to the following equation:

C U = C M + C L + C T + C E + C OH
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The following tables depict the cost comparison of the original and Remodeled Design:
Table 8 & 9: Unit Cost Comparison Between Original and Redesign

Simply reducing the parts dropped the cost by $2.30, even though the three redesigned
parts were more complicated relative to the other components.
The next cost estimate implemented was the Order of Magnitude Estimate (OME). The
OME is usually used to ballpark the cost of materials, manufacture, and the sales price. The
following equation is used to predict such estimates:
OM E material = (1 + f raction of waste) * material cost * material weight

OM E manuf acture = 3 * OM E material

OM E P rice = 9 * OM E manuf acture

The following tables depicts the OME cost comparison of the original and remodeled design:
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Table 10: OME cost of Original Design

Table 11: OME cost of Remodeled Design


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The total OME cost of the original and remodeled design were $21.187 and $22.72
respectively, this estimator is simply another form of verification to the team’s cost analysis of
the product. Moreover, CustomPart.net, an online quoting source, was used to provide the
estimated manufacturing cost of the both original and remodeled design and is displayed in the
following table:
Table 12 & 13: CustomPart.net quote estimate of Original and Remodeled Design

The remodel design reduced the cost by $0.632. Even though this change is small, the difference
becomes noticeable over a large product run.Finally, a break-even point analysis was created, the
team sought to determine the break-even sales price at 5,000 units. The break-even is given by
the following equation:
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The following table is the break-even analysis comparison of the original and remodeled design:
Table 14: Break-even analysis of 5,000 units of the original and remodeled design

A 33% reduction of the sales price was found with the remodeled design. The team is
confident with the cost analysis, since all cost estimates used proved the remodeled design would
reduce the cost with the proposed design changes.
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Assembled View
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Professional, ethical, and safety considerations


The coffee grinder is a product for the user who prefers to grind their own coffee beans
into grounds. On average, 83% of americans drink coffee 4 . Because the target audience is so
large, the design for the grinder was made simple to use. Any user can understand how the
product works. Plus the coffee grinder is compact, fitting easily in shelves or cabinets. These
considerations are important because if the design was too complicated, bulky, or uneasy to look
at, the product would not sell.
The aesthetic of the grinder is a metallic, almost chrome, shade of grey. The product is
not meant to be an eye catcher or centerpiece of a kitchen table. The grinder is a tool and is
aesthetically designed to look as a kitchen appliance. There is no labeling on the outside pieces
and there are no words advertised.
The coffee grinder is a product that explains its function in the title; a product the grinds
coffee. The original design keeps the sharp blades within the space of the cup that holds the
coffee beans. While it is possible for a child to stick their finger into the area of the blade while
turning the handle, the space is very small and is unlikely that a child could manage to
accomplish this.
Another safety consideration found is the ability to disassemble the product. This allows
the user to clean the hard to get places. For example, if coffee grounds were getting stuck
between the blades and the grinder core, the user would have to access the area and clean away
any excess debris. This increases the chance of the user injuring themselves. Disassembly allows
for ease of cleaning. The blades will still be sharp to the touch and can be dangerous when being
held but isolating each component is safer than inserting a finger into a hole or crevice in an
attempt to clear debris.
The consideration of disassembly is important for cleaning and ease of use. However,
there exist small objects in the assembly. Adults will mainly use the product, but if disassembled
pieces are left unattended, a child could swallow or choke on the small objects. This situation is
difficult to avoid but must be addressed in an instruction manual at least.
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Conclusion
The Vomach Manual Coffee Grinder is the simplest of kitchen appliances that requires
inserting coffee beans in a cup plus a twisting motion that results in the ultimate output of coffee
grounds which are used to brew coffee. The design of the coffee grinder is simple and was found
to be effective for its use. The grinder can adjust the fineness of the grounds desired. Having this
flexibility is positive for user marketability. The product was assessed through the reverse
engineering process with exceptional attention to detail. The simplicity of the product plus the
effectiveness of its use brought a drive for knowledge and research. These reasons made the
product a prime candidate for design for manufacturability (DFM) and design for assembly
(DFM) analysis.
During the disassembly process, it was obvious the coffee grinder was originally built
with aspects of DFA in mind. The center core was found to hold almost all the components
together. The process took the team only about 10 minutes, showing the products intent; ease of
disassembly. Coffee grounds are small particles that can get into hard to reach areas. Being able
to easily disassemble the product to clean away coffee powder is a clear user accessibility intent.
Coffee grounds do not necessarily get ‘dirty,’ but a change in coffee beans with leftover grounds
from the previous bean would result in a mix of flavors, most likely undesirable for the user.
An analysis of component material was made, resulting in the conclusion of mostly die
casted parts. The components which are tapped and fastened to the threaded rod are unique in
shape and the process of die casting was determined to be the most economical process. The
majority of the body is made of a stainless steel (most likely 300 series.) This specific series of
stainless steel most notably resists corrosion well. The components which grind the coffee beans
into powder were undetermined in material, but were identified to be of either a ceramic material
or Alumina. However, it was determined that the process to create the grinders was sand casting.
Sand casting provides greater dimensional accuracy, so it would create the profiles of the sharp
edges well.
The reassembly plus consumer use of the product saw three possible redesigns. The team
found a design that improves the number of parts for assembly greatly. Two fasteners are used to
attach five components together. A design where all five components are as one was created. The
part, however, is very complex and would be expensive to manufacture. The design also
combines what was two different materials, so a new material must be chosen that will have the
hardness of the blades with the structural and weight properties of the outer body. This may
increase the manufacture cost, but was shown to greatly decrease the number of parts, improving
DFA categories. The handle consists of three components of three different materials. A redesign
for easier assembly processes was made by creating a more complex part with the same
functionality of the current design. The last redesign follows the pattern of reducing parts by
combining three components from the collection receptacle subassembly. With the three
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redesigns combined, the DFA categories drastically improved and the unit cost reduced for the
product.
The reverse engineering process is advantageous for any product. Flaws as well as
strengths in design are found that original designers could have missed. It is impossible to know
the exact intent of the owner, but reverse engineering allows a team to gain knowledge and
experience of a product without any interaction of an original designer. The coffee grinder
showed the team that designs should be kept simple. The biggest drive in the marketplace is
price. The lower the price of a product can be without sacrificing usability creates a marketable
and successful product.
Reverse Engineering of a Manual Coffee Grinder Page 54​ of 55
Al-Weqayyan, Liu, Perkey, Yearout MCEN 5045

References
1.Riffell, Dan. “Lecture 12.” MCEN 5045 Spring 2018. Boulder, CO. February 2018. Lecture.
2.Riffell, Dan. “Lecture 13.” MCEN 5045 Spring 2018. Boulder, CO. February 2018. Lecture.
3.Riffell, Dan. “Lecture 11.” MCEN 5045 Spring 2018. Boulder, CO. February 2018. Lecture.
4.Fernau, Karen. “Coffee grinds fuel for the nation.” ​The Arizona Republic​. USA Today. March 2018.
Website. URL:
​https://www.usatoday.com/story/money/business/2013/04/09/coffee-mania/2069335/
Reverse Engineering of a Manual Coffee Grinder Page 55​ of 55
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Appendices

Appendix A
Orthographic Drawings
6 5 4 3 2 1
REV. DESCRIPTION DATE
A INITIAL RELEASE 2/27/2018

NOTES:
1. ITEM NUMBER 1 AND 9 ARE SUB ASSEMBLIES

QTY.
ITEM NO. PART NUMBER
15
A A
9

1 2001 1
2 1004 1
3 1016 1
4 1012 1
5 1019 1
6 1007 1 5
7 1003 1
8 1001 1 6
9 2002 1
B 10 1008 1
B
11 1015 1
12 1011 1
7
13 HFBOLT 0.25-28x0.875x0.875-N 2
14 HNUT 0.2500-28-D-N 2
15 1005 1 2 8

4 3

13

12 1
C C

10 14

11

UNIVERSITY OF COLORADO
COFFEE GRINDER
1111 ENGINEERING DRIVE
D BOULDER, CO 80309-0427 D
DESCRIPTION
COFFEE GRINDER ASSEMBLY
PN REV SHEET
2000 A 1 of 1
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE
PROPERTY OF UNIVERSITY OF COLORADO. ANY REPRODUCTION IN
PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS
PROHIBITED.

6 5 4 3 2 1
6 5 4 3 2 1
REV. DESCRIPTION DATE
A INITIAL RELEASE 2/27/2018

QTY.
ITEM NO. PART NUMBER

A A

1 1017 1
2 1013 1
3 1009 1 1
4 1002 1
5 HHNUT 0.3125-18-D-N 1

B B

C C

UNIVERSITY OF COLORADO
GRINDING CORE
1111 ENGINEERING DRIVE
D BOULDER, CO 80309-0427 D
DESCRIPTION
GRINDING CORE
PN REV SHEET
2001 A 1 of 1
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE
PROPERTY OF UNIVERSITY OF COLORADO. ANY REPRODUCTION IN
PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS
PROHIBITED.

6 5 4 3 2 1
6 5 4 3 2 1
REV. DESCRIPTION DATE
A INITIAL RELEASE 2/27/2018

QTY.
ITEM NO. PART NUMBER

A A

1 1006 1
2 1014 1
3 1010 1

B B
3

C C

UNIVERSITY OF COLORADO
UPPER BODY
1111 ENGINEERING DRIVE
D BOULDER, CO 80309-0427 D
DESCRIPTION
UPPER BODY
PN REV SHEET
2002 A 1 of 1
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE
PROPERTY OF UNIVERSITY OF COLORADO. ANY REPRODUCTION IN
PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS
PROHIBITED.

6 5 4 3 2 1
REV. DESCRIPTION DATE
A INITIAL RELEASE 1/29/2018
2.214

.134
.664

1.428

R.519 THRU

.214 THRU

.203

TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO


UNLESS X.XX 0.010
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION

CERAMIC COFFEE GRINDER OUTER CORE


FINISH PN REV SHEET
N/A 1002 A 1 of 3
PROPRIETARY AND THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF COLORADO.
CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS PROHIBITED.
64°
A A

.024

.060
B
DETAIL B
SCALE 8 : 1

.238

SECTION A-A

UNIVERSITY OF COLORADO

1111 ENGINEERING DRIVE


BOULDER, CO 80309-0427
DESCRIPTION
NOTES:
COFFEE GRINDER OUTER CORE
A. X60 SMALL GRINDER TEETEH EQUALLY SPACED APART AND ALL OF THE SAME DIMENSIONS PN REV SHEET
B. TEETH ARE ROTATED BY 6 DEGREES FROM TOP TO MIDDLE IN A CCW DIRECTION 1002 A 2 of 3
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE
PROPERTY OF UNIVERSITY OF COLORADO. ANY REPRODUCTION IN
PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS
PROHIBITED.
65°

.053

.219
C
DETAIL C
SCALE 4 : 1

UNIVERSITY OF COLORADO

1111 ENGINEERING DRIVE


BOULDER, CO 80309-0427
NOTES: DESCRIPTION

A. X16 LARGE GRINDER TEETH EQUALLY SPACED APART AND ALL OF THE SAME DIMENSIONS COFFEE GRINDER OUTER CORE
PN REV SHEET
B. TEETH ARE ROTATED BY 22.5 DEGREES FROM THE BOTTOM TO MID IN A CCW DIRECTION
1002 A 3 of 3
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE
PROPERTY OF UNIVERSITY OF COLORADO. ANY REPRODUCTION IN
PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS
PROHIBITED.
REV. DESCRIPTION DATE
A INITIAL RELEASE 3/2/18

NOTES:
1.REFER TO CAD FOR COMPLEX GEOMETRY

5X R.22

5X .40 .300 THRU


A SECTION A-A

.25

.65
.29

69°

A R.52

3X .400

.75

5X 60°
TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO
UNLESS X.XX 0.010 MCEN 5045
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION

CERAMIC INNER GRINDER BLADE


FINISH PN REV SHEET
NONE 1013 A 1 of 1
R.575 PROPRIETARY AND THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF COLORADO.
CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS PROHIBITED.
REV. DESCRIPTION DATE
A INITIAL RELEASE 2/7/18

.05 .10

R.25

3X R.50

.275 THRU

3X 60°

TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO


UNLESS X.XX 0.010 MCEN 5045
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION

304 STAINLESS STEEL CENTER BLADE


FINISH PN REV SHEET
NONE 1009 A 1 of 1
PROPRIETARY AND THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF COLORADO.
CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS PROHIBITED.

SOLIDWORKS Educational Product. For Instructional Use Only.


REV. DESCRIPTION DATE
A INITIAL RELEASE 3/2/18

2X R.108

.275

2X .15

#5-40 Machine Threads

.50

#5-40 Machine Threads

3.00

TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO


UNLESS X.XX 0.010 MCEN 5045
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION

304 STAINLESS STEEL THREADED ROD


FINISH PN REV SHEET
NONE 1017 A 1 of 1
PROPRIETARY AND THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF COLORADO.
CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS PROHIBITED.
#5-40 Thread

5/16" 7/64"

PART
NUMBER 90480A006
http://www.mcmaster.com Hex
© 2015 McMaster-Carr Supply Company
Information in this drawing is provided for reference only.
Nut
REV. DESCRIPTION DATE
A INITAL RELEASE 1/31/2018
B UPDATED DIMENSIONS AND GD&T 3/4/2018

A
.143
.136 .497

A
.035 TYP SECTION A-A

2.109 2.607 2.915

.214 THRU

1.335 THRU

TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO


UNLESS X.XX 0.010
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION

304 STAINLESS STEEL COFFEE GRINDER - MID BODY


FINISH PN REV SHEET
NOTES: NONE 1006 B 1 of 1
A. ALL RADII BOTH INTERNALLY AND EXTERNALLY ARE 0.050 INCHES PROPRIETARY AND THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF COLORADO.
CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS PROHIBITED.
REV. DESCRIPTION DATE
2X.889 A INITAL RELEASE 2/6/2018
B GD&T TOLERANCING 2/12/2018

.214 THRU

2.938 NOTES:
A. THE THICKNESS OF THIS PART IS 0.070
INCHES
1.248 THRU
B. NO HARD EDGES ON ANY CUTS OR
FEATURES
C. TOP LIP IS ROLLED OVER ONTO THE
.005 B OUTER WALL OF THE PART
.005 D. PART SHOULD MATE WITH PART NUMBER
1006

4.059

R2.00
1.45
.01 A

TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO


UNLESS X.XX 0.010
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
A UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION

304 STAINLESS STEEL COFFEE GRINDER - UPPER BODY


FINISH PN REV SHEET
NONE 1010 B 1 of 1
PROPRIETARY AND THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF COLORADO.
CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS PROHIBITED.
REV. DESCRIPTION DATE
A INITIAL RELEASE 2/22/2018

.493
2.36
.209 R.05 [TYP]

102°

.659
.53 .46

2X R.10 SECTION A-A


SCALE 2 : 1
.05

1.777
2X .214

A A NOTES:
1. BREAK ALL EDGES
2. UNIFORM THICKNESS OF 0.05
3. USE CAD FOR REFERENCE OF COMPLEX GEOMETRIES
3.35
4. DEPTH OF THE EXTRUSIONS ARE 0.040''

1.40
TOLERANCES X.X 0.05 UNIVERSITY OF COLORADO
UNLESS X.XX 0.01
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
2X .89 UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION

304 STAINLESS STEEL COFFEE GRINDER-COVER


FINISH PN REV SHEET
NONE 1014 A 1 of 2
PROPRIETARY AND THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF COLORADO.
CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS PROHIBITED.
A

.120

.020

DETAIL A
8X .03 SCALE 4 : 1

4X 19°

8X .07

UNIVERSITY OF COLORADO

1111 ENGINEERING DRIVE


BOULDER, CO 80309-0427
DESCRIPTION
COFFEE GRINDER-COVER
PN REV SHEET

EXTRUSION SHALL BE PLACED AT EVERY 90 1014 A 2 of 2


PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE
PROPERTY OF UNIVERSITY OF COLORADO. ANY REPRODUCTION IN
PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS
PROHIBITED.
REV. DESCRIPTION DATE
R.11 A INITIAL RELEASE 1/30/18

.581

R.11

R.17
.09

3.200

DETAIL A
SCALE 2 : 1
A

3.00
3.303
1.58
NOTES:
1.UNIFORM THICKNESS OF 0.010"

3.790

R.10 [TYP]
TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO
R.17 UNLESS X.XX 0.010 Coffee Grinder Base
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION

304 STAINLESS STEEL COFFEE GRINDER BASE


FINISH PN REV SHEET
DETAIL B NONE 1008 A 1 of 2
SCALE 1 : 1 PROPRIETARY AND THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF COLORADO.
CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS PROHIBITED.
+.000 NOTES:
.01 - .005 EXTRUSION SHALL BE PLACED AT EVERY 90

1.177
.114

.414

.022
.108

DETAIL AR
SCALE 1 : 1
DETAIL AL
SCALE 2 : 1

AR
AK
AL

AK UNIVERSITY OF COLORADO
Coffee Grinder Base
SECTION AK-AK 1111 ENGINEERING DRIVE
BOULDER, CO 80309-0427
DESCRIPTION
COFFEE GRINDER BASE
PN REV SHEET
1008 A 2 of 2
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE
PROPERTY OF UNIVERSITY OF COLORADO. ANY REPRODUCTION IN
PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS
PROHIBITED.
REV. DESCRIPTION DATE
1 INITIAL RELEASE 1/29/18

R.26

30X R.04

30X .05
R.67

A .20

.20 .19

.53 B .55

.33 R.16

.15

A DETAIL B SECTION A-A


SCALE 6 : 1 SCALE 3 : 1 1/4-20 UNC

.28
TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO
UNLESS X.XX 0.010 MCEN 5045
NOTED:
.49 X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION

304 STAINLESS STEEL CAP OF GRINDER ASSEMBLY


FINISH PN REV SHEET
N/A 1001 1 1 of 1
PROPRIETARY AND THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF COLORADO.
CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS PROHIBITED.
REV. DESCRIPTION DATE
NOTES: A INITIAL RELEASE 1/29/2018
1. REFER TO CAD MODEL FOR COMPLEX GEOMETRY

4.1
3.75
3.23 .15 R.3

A
.18
1.3

R.13 DETAIL A
R.30 SCALE 1 : 1
4.72
.200 R5.4 5.09

R4.5

3.7
2.9

R.4
.12 TYP

TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO


UNLESS X.XX 0.010
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
150° UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION

304 STAINLESS STEEL GRINDER CRANK


R.4 FINISH PN REV SHEET
N/A 1003 A 1 of 1
PROPRIETARY AND THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF COLORADO.
CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS PROHIBITED.
REV. DESCRIPTION DATE
A INITIAL RELEASE 1/28/18
B POST INSTRUCTOR FEEDBACK 2/4/2018

.26

THRU ALL

.10 2X R.73
.20 2X .22

2X R.400

2X .25

.96

2X .10

2X 1.15

2X R.01 TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO


UNLESS X.XX 0.010 U-connector
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION

304 STAINLESS STEEL U-CONNECTOR


FINISH PN REV SHEET
.10 2X R.05 NONE 1004 B 1 of 1
PROPRIETARY AND THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF COLORADO.
CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS PROHIBITED.
REV. DESCRIPTION DATE
A INITIAL RELEASE 2/1/18
.09±.020 B ADDED DIMENSIONS TOSPOKE PATTERN 3/2/18

.09±.01
.21±.050

7X .15±.050

6X .09±.010

+.005
.04 - .000
1.70±.050

6x 60°

6X R1.00±.050

R2.03±.050
6X R1.70±.010
SECTION A-A
SCALE 1 : 1
A
TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO
UNLESS X.XX 0.010 MCEN 5045
+.000 NOTED:
R1.85 - .050 X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION

NATURAL RUBBER RUBBER COVER


6x 60° FINISH PN REV SHEET
NONE 1005 B 1 of 1
PROPRIETARY AND THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF COLORADO.
CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS PROHIBITED.
REV. DESCRIPTION DATE
A INITIAL RELEASE 1/31/2018

R.600 R.300

.43

.09
.12
1.4

.30 .02 R.250 R.200

R.200

.34 .02

R.220

TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO


UNLESS X.XX 0.010
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION

OAK WOODEN CRANK HANDLE


FINISH PN REV SHEET
N/A 1007 A 1 of 2
PROPRIETARY AND THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF COLORADO.
CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS PROHIBITED.
.94
.80
.76
.30

.20 THRU

.64
.66
UNIVERSITY OF COLORADO
.80
1111 ENGINEERING DRIVE
BOULDER, CO 80309-0427
DESCRIPTION
WOODEN CRANK HANDLE
PN REV SHEET
1007 A 2 of 2
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE
PROPERTY OF UNIVERSITY OF COLORADO. ANY REPRODUCTION IN
PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS
PROHIBITED.
REV. DESCRIPTION DATE
A INITIAL RELEASE 2/5/2018

.008 TYP

2.7

3.0

TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO


UNLESS X.XX 0.010
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION

304 STAINLESS STEEL O-RING ON LOWER CHMBER


FINISH PN REV SHEET
N/A 1011 A 1 of 1
PROPRIETARY AND THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF COLORADO.
CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS PROHIBITED.
REV. DESCRIPTION DATE
.32 .005 THRU ALL A INITIAL RELEASE 2/6/2018
.010 M A C B
106° .34 2X R.40
92°

2X .214 THRU ALL


.010 M A C B

C 2X .60
2X .89 2X .30
.21
2.20

.001 2X .05
R.05 [TYP] 2X .766
.001 C
2X .289

+.01
.01 - .00
2X .05
2X 1.028

2X 1.48
B
.05

.33

TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO


UNLESS X.XX 0.010 Bolt-Connector
NOTED:
DETAIL B .50 X.XXX 0.005 1111 ENGINEERING DRIVE
SCALE 4 : 1 UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
DESCRIPTION
.60 MATERIAL
304 STAINLESS STEEL BOLT-CONNECTOR
A FINISH PN REV SHEET
NONE 1012 A 1 of 1
PROPRIETARY AND THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF COLORADO.
CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS PROHIBITED.
REV. DESCRIPTION DATE
A INITIAL RELEASE 2/6/2018

.10

B
C

6X 30°
R.400
5X 30°

.287 THRU ALL


R.500 0.01 M C A B

R.025 [TYP]

0.01 C 5-40 THREAD

TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO


UNLESS X.XX 0.010
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION

304 STAINLESS STEEL GEAR


FINISH PN REV SHEET
NONE 1016 A 1 of 1
PROPRIETARY AND THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF COLORADO.
CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS PROHIBITED.
REV. DESCRIPTION DATE
A INITIAL RELEASE 2/8/2018
B REWORK ACCORDING RIVET DATASHEET 2/25/2018

1.563

.313 .136 .188

.060 .155

TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO


UNLESS X.XX 0.010
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION

430 STAINLESS STEEL RIVET USED TO HOLD HANDLE


FINISH PN REV SHEET
N/A 1019 B 1 of 1
PROPRIETARY AND THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF COLORADO.
CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS PROHIBITED.
1/4"-28 Thread

7/16" 7/32"

PART
NUMBER 90490A205
http://www.mcmaster.com Hex
© 2015 McMaster-Carr Supply Company
Information in this drawing is provided for reference only.
Nut
7/16" 11/64" 7/8"
Hex

0.25"

1/4"-28 Thread

PART
NUMBER 92620A565
http://www.mcmaster.com High-Strength Steel
© 2014 McMaster-Carr Supply Company
Information in this drawing is provided for reference only.
Cap Screw-Grade 8
6 5 4 3 2 1
REV. DESCRIPTION DATE
ITEM NO. PART NUMBER DESCRIPTION QTY. A INITIAL RELEASE 3/5/2018
1 1004 U-CONNECTOR 1
2 1016 GEAR 1
3 1001 Cap of Grinder Assembly 1
A 4 1014R GRINDER AND UPPER BODY REDESIGN 1 A
5 1003R REDESIGNED CRANK & HANDLE 1
6 1008R COLLECTION RECEPTICLE 1
7 1009 CENTER BLADE 1 11

8 1013 INNER GRINDER BLADES 1


3
9 1017 THREADED ROD 1
10 HHNUT 0.3125-18-D-N HEX NUT 1 5

11 1005 RUBBER COVER 1

B B

4
C C
7

10

UNIVERSITY OF COLORADO

1111 ENGINEERING DRIVE


D BOULDER, CO 80309-0427 D
DESCRIPTION
REMODEL DESIGN ASSEMBLY
PN REV SHEET
2000R A 1 of 1
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE
PROPERTY OF UNIVERSITY OF COLORADO. ANY REPRODUCTION IN
PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS
PROHIBITED.

6 5 4 3 2 1
REV. DESCRIPTION DATE
A INITIAL RELEASE 3/4/2018

.12 TYP .25

A Tag Direction Angle Inner Radius

A DOWN 200° 0.15

B B UP 100° 0.03

7.5
C DOWN 60° 0.03

6.3 D UP 60° 0.03

4.7

C
D
1.2
.8
A

.18
R.13

TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO


UNLESS X.XX 0.010
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
.15 UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION

R.3 304 STAINLESS STEEL REDESIGNED CRANK & HANDLE


DETAIL A FINISH PN REV SHEET
N/A 1003R A 1 of 1
SCALE 1 : 1
PROPRIETARY AND THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF COLORADO.
CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS PROHIBITED.
REV. DESCRIPTION DATE
NOTES:
A INITIAL RELEASE 3/2/2018
1. UNIFORM THICKNESS OF 0.010''
R.11 2. BREAK ALL EDGES

.58

R.11 .09
3.19

DETAIL B
SCALE 2 : 1

3.41
1.68

3.79

R.10 [TYP]
TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO
2X R.17 UNLESS X.XX 0.010
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION

304 STAINLESS STEEL COLLECTION RECEPTICLE


FINISH PN REV SHEET
NONE 1008R A 1 of 2
DETAIL A
PROPRIETARY AND THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF COLORADO.
SCALE 2 : 1 CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS PROHIBITED.
1.178
+.000
.01 - .005
.419
.114

.108

.025 DETAIL F
EXTRUSION SHALL BE PLACED AT EVERY 90 SCALE 1 : 1

DETAIL E
SCALE 2 : 1

C F
E

.06 D SECTION C-C C


DETAIL D UNIVERSITY OF COLORADO
SCALE 4 : 1
.113 1111 ENGINEERING DRIVE
BOULDER, CO 80309-0427
DESCRIPTION
COLLECTION RECEPTICLE
PN REV SHEET
1008R A 2 of 2
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE
PROPERTY OF UNIVERSITY OF COLORADO. ANY REPRODUCTION IN
PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS
PROHIBITED.
R.050 112° REV. DESCRIPTION DATE
A INITIAL RELEASE 3/5/18

.325
60X .024
60X 70°
.050
.908 R.519 THRU
102°
78°
2.407
1.408
.070 60X .060
R2.001 DETAIL F
76°
.960 SCALE 8 : 1
SECTION C-C
.240 SCALE 1 : 1
1.428 1.248
1.280
.175 .600
1.428
3.350 R.400 F .500
.320 THRU
4.059
3.919

2.938
4° .449 .564

C C

DETAIL D
SCALE 2 : 1

D
1.280
TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO
UNLESS X.XX 0.010 MCEN 5045
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION

STAINLESS STEEL GRINDER CORE REDESIGN


FINISH PN REV SHEET
NONE 1014R A 1 of 2
PROPRIETARY AND THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF COLORADO.
CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS PROHIBITED.

SOLIDWORKS Educational Product. For Instructional Use Only.


H

.467

8X .069

8X .069

DETAIL P
16X .140
SCALE 2 : 1

16X.043

16X 65° TOLERANCES X.X 0.050 UNIVERSITY OF COLORADO


UNLESS X.XX 0.010 MCEN 5045
NOTED:
X.XXX 0.005 1111 ENGINEERING DRIVE
UNITS: INCHES X.X 1 BOULDER, CO 80309-0427
MATERIAL DESCRIPTION

STAINLESS STEEL GRINDER CORE REDESIGN


FINISH PN REV SHEET
NONE 1014R A 2 of 2
PROPRIETARY AND THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF COLORADO.
CONFIDENTIAL ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT WRITTEN PERMISSION IS PROHIBITED.

SOLIDWORKS Educational Product. For Instructional Use Only.


Appendix B
DFA Analysis - Original Design
DFA Analysis Worksheet
Assembly Name: Mechanical Coffee Grinder Team: Coffee Date: 2/18/2018
If the answer is Yes to any of the metrics or questions enter a 1. If the answer is No then enter 0. Each cell must have a number.
DFA Functional Analysis / Error
Part Complexity Redesign Opportunity Proofing Handling Insertion Secondary Operations

Part Can Be Standardized (if

Assemble Part Wrong Way


Theoretical Minimum Part

Cost (Low/Medium/High)
Number of Interfaces (Ni)

Magnifying Glass Needed


Flexible, Fragile, Sharp or

Screw, Drill, Twist, Rivet,


Difficult to Align/ Locate
not already standard)

Paint, Lube, Heat, Apply

Test, Measure or Adjust


Holding Down Required
Practical Minimum Part

Resistance to Insertion
Assemble Wrong Part/

Pliers, Tweezers, or
Number of Parts (Np)

Weld, Solder, or Glue


Tangle, Nest, or Stick

Re-orient Workpiece

Bend, or Crimp
Obstructed Access/

Liquid or Gas
Around

Slippery
Omit Part

Together

Visibility
Part Number Part Name
Sub Assem 1 Grinding Core
1017 Threaded Rod 1 7 1 1 M 1 0 0 0 0 0 0 0 0 0 0 1 0 0 0
1009 Center Blade 1 1 0 0 H 1 0 1 1 1 0 0 0 0 0 0 0 0 0 0
1013 Inner Blade Piece 1 3 1 0 H 1 0 0 0 0 0 0 0 0 0 0 1 0 0 0
1002 Coffee Grinder- Core 1 4 1 0 H 1 0 0 0 1 0 1 1 0 0 0 0 0 0 0
Sub Assem 2 Upper Body
1014 Coffee Grinder - Cover 1 3 1 0 M 1 0 0 0 1 0 0 0 0 0 0 1 0 0 0
1006 Coffee Grinder - Mid 1 2 0 0 H 0 0 0 1 1 0 1 1 0 0 0 1 0 0 0
1010 Coffee Grinder - Upper 1 3 0 0 H 1 0 0 1 1 0 1 1 0 0 0 1 0 0 0
Sub Assemb 3 Manual Crank System
1012 Bolt Connector 1 4 0 0 L 1 0 0 0 0 0 1 1 0 0 0 0 0 0 0
1016 Gear 1 3 0 1 L 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0
1004 U- connector 1 2 1 0 M 1 0 0 1 0 0 0 0 0 0 0 0 0 0 0
1003 Crank 1 4 0 0 M 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0
1018 Rivet 1 2 0 1 L 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0
1007 Handle 1 2 0 0 M 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
1001 Grinder Cap 1 2 1 1 L 1 0 0 0 0 0 0 0 0 0 0 1 0 0 0
Sub Assemb 4 Collection Recepticle
1011 O-ring 1 1 1 0 L 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0
1008 Coffee Grinder-Base 1 3 0 0 H 1 0 0 0 1 0 0 0 0 0 0 1 1 0 0
1015 Bottom Cap 1 1 0 0 L 0 0 0 0 1 0 0 0 0 0 0 0 1 0 0
1005 Rubber Cover 1 1 0 0 M 1 0 0 0 1 0 0 0 0 0 0 0 0 0 0
1020 Fasteners 2 2 2 1 L 2 0 0 0 0 0 1 1 0 0 1 0 0 0 0
1019 Nuts 3 2 3 1 L 3 0 0 0 0 0 0 0 0 1 0 1 0 0 0
Totals 23 52 12 6 0 18 0 1 4 9 0 5 5 0 1 1 9 2 0 0
←Theor. Effy.
Design for Assembly Metrics 34.58323293 52.2% Pract. Effy.→ 78.3% 0.08 1.08 0.92 1.00
Targets 60.0%
Appendix C
DFA Analysis - Redesign
DFA Analysis Worksheet
Assembly Name: Mechanical Coffee Grinder Team: Coffee Date: 2/28/2018
If the answer is Yes to any of the metrics or questions enter a 1. If the answer is No then enter 0. Each cell must have a number.
DFA Functional Analysis / Error
Part Complexity Redesign Opportunity Proofing Handling Insertion Secondary Operations

Part Can Be Standardized (if

Assemble Part Wrong Way


Theoretical Minimum Part

Cost (Low/Medium/High)
Number of Interfaces (Ni)

Magnifying Glass Needed


Flexible, Fragile, Sharp or

Screw, Drill, Twist, Rivet,


Difficult to Align/ Locate
not already standard)

Paint, Lube, Heat, Apply

Test, Measure or Adjust


Holding Down Required
Practical Minimum Part

Resistance to Insertion
Assemble Wrong Part/

Pliers, Tweezers, or
Number of Parts (Np)

Weld, Solder, or Glue


Tangle, Nest, or Stick

Re-orient Workpiece

Bend, or Crimp
Obstructed Access/

Liquid or Gas
Around

Slippery
Omit Part

Together

Visibility
Part Number Part Name
1001 Grinder Cap 1 2 1 1 L 1 0 0 0 0 0 0 0 0 0 0 1 0 0 0
1017 Threaded Rod 1 5 1 1 M 1 0 0 0 0 0 0 0 0 0 0 1 0 0 0
1009 Center Blade 1 1 0 0 H 1 0 1 1 1 0 0 0 0 0 0 0 0 0 0
1013 Inner Blade Piece 1 3 1 0 H 1 0 0 0 0 0 0 0 0 0 0 1 0 0 0
1014R Coffee Grinder - Upper Body 1 3 1 0 H 1 0 0 0 1 0 0 0 0 0 0 1 0 0 0
1016 Gear 1 3 1 1 L 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0
1004 U- connector 1 2 1 0 M 1 0 0 1 0 0 0 0 0 0 0 0 0 0 0
1003R Handle 1 2 1 0 H 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0
1008R Collection Recepticle 1 1 1 0 H 1 0 0 0 1 0 0 0 0 0 0 1 1 0 0
1018 Nuts 1 1 1 1 L 1 0 0 0 0 0 0 0 0 1 0 1 0 0 0
Totals 10 23 9 4 0 10 0 1 2 3 0 0 0 0 1 0 6 1 0 0
←Theor. Effy.
Design for Assembly Metrics 15.16575089 90.0% Pract. Effy.→ 100.0% 0.11 0.56 0.11 0.78
Targets 60.0%
Appendix D
DFA Cost Analysis - Original
Design
Parameters Grinder Cap Coffee Grinder-Core Crank U-connector Rubber Cover
Part: 1001 1002 1003 1004 1005
Cm $0.03 $0.10 $0.10 $0.05 $0.07
m (weight) 0.02 0.044 0.07 0.03 0.024
cm (cost) 1.29 1.83 1.29 1.29 2.18
f ( fraction of waste) 0.1 0.2 0.1 0.2 0.2

Cl $0.13 $0.13 $0.13 $0.13 $0.13


Cw ( hourly cost) 25 25 25 25 25
n' (production rate) 200 200 200 200 200

Ct $0.10 $0.25 $0.04 $0.10 $0.13


ct (cost of tooling) 20000 50000 7500 20000 25000
n ( entire production run) 500000 500000 500000 500000 500000
k ( tooling wear factor) 2.5 2.5 2.5 2.5 2.5

Ce $0.05 $0.10 $0.05 $0.05 $0.13


ce ( cost of capital equipment) 200000 400000 200000 200000 500000
n' (production rate) 200 200 200 200 200
t_two (capital write off time (yrs) 5 5 5 5 5
L (load factor) 1 1 1 1 1
q ( fraction of equipment sharing between product) 1 1 1 1 1

Coh $0.30 $0.30 $0.30 $0.30 $0.30


coh ( overhead hourly rate) 60 60 60 60 60
n' (production rate) 200 200 200 200 200

Total Cu per part $0.60 $0.88 $0.61 $0.62 $0.74

Total Cu $13.71

Order of Magnitude Estimate Manufacture Cost- Q


Part cost Mfg cost Sales Price
1001 $0.028 $0.085 $0.255 $0.361
1002 $0.097 $0.290 $0.870 $0.402
1003 $0.099 $0.298 $0.894 $0.197
1004 $0.046 $0.139 $0.418 $0.197
1005 $0.063 $0.188 $0.565 $0.197
1006 $0.135 $0.404 $1.212 $0.363
1007 $0.019 $0.058 $0.173 $0.168
1008 $0.302 $0.906 $2.717 $0.363
1009 $0.011 $0.034 $0.102 $0.168
1010 $0.567 $1.700 $5.101 $0.363
1011 $0.004 $0.013 $0.038 $0.197
1012 $0.084 $0.252 $0.755 $0.197
1013 $0.128 $0.385 $1.156 $0.197
1014 $0.319 $0.956 $2.868 $0.361
1015 $0.158 $0.473 $1.418 $0.361
1016 $0.028 $0.085 $0.255 $0.361
1017 $0.065 $0.196 $0.587 $0.421
1018 $0.154 $0.154
1019 $1.019 $1.019
1020 $0.630 $0.630
Total $21.187 $6.677
Grinder Mid Body Handle Coffee Grinder-Base Blade Coffee Grinder-Upper O-ring Bolt connector Inner Blade Piece
1006 1007 1008 1009 1010 1011 1012 1013

$0.14 $0.02 $0.33 $0.01 $0.62 $0.00 $0.09 $0.13


0.087 0.014 0.18 0.008 0.338 0.003 0.05 0.083
1.29 1.25 1.29 1.29 1.29 1.29 1.29 1.29
0.2 0.1 0.3 0.1 0.3 0.1 0.3 0.2

$0.13 $0.13 $0.13 $0.13 $0.13 $0.13 $0.13 $0.13


25 25 25 25 25 25 25 25
200 200 200 200 200 200 200 200

$0.15 $0.10 $0.25 $0.20 $0.25 $0.04 $0.10 $0.25


30000 20000 50000 40000 50000 7500 20000 50000
500000 500000 500000 500000 500000 500000 500000 500000
2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5

$0.05 $0.03 $0.05 $0.05 $0.05 $0.05 $0.05 $0.10


200000 100000 200000 200000 200000 200000 200000 400000
200 200 200 200 200 200 200 200
5 5 5 5 5 5 5 5
1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1

$0.30 $0.30 $0.30 $0.30 $0.30 $0.30 $0.30 $0.30


60 60 60 60 60 60 60 60
200 200 200 200 200 200 200 200

$0.77 $0.57 $1.06 $0.69 $1.35 $0.52 $0.67 $0.91

Manufacture Cost- Quote Comparison Breakeven for 5000 parts


Labor cost Material cost G&A Depreciation Factory ExpensesSales and OH
$0.50 $0.03 $1,200.00 $5,000.00 $800.00 $1,000.00
$0.50 $0.10 $1,200.00 $5,000.00 $800.00 $1,000.00
$0.50 $0.10 $1,200.00 $5,000.00 $800.00 $1,000.00
$0.50 $0.05 $1,200.00 $5,000.00 $800.00 $1,000.00
$0.50 $0.06 $1,200.00 $5,000.00 $800.00 $1,000.00
$0.50 $0.13 $1,200.00 $5,000.00 $800.00 $1,000.00
$0.50 $0.02 $1,200.00 $5,000.00 $800.00 $1,000.00
$0.50 $0.30 $1,200.00 $5,000.00 $800.00 $1,000.00
$0.50 $0.01 $1,200.00 $5,000.00 $800.00 $1,000.00
$0.50 $0.57 $1,200.00 $5,000.00 $800.00 $1,000.00
$0.50 $0.00 $1,200.00 $5,000.00 $800.00 $1,000.00
$0.50 $0.08 $1,200.00 $5,000.00 $800.00 $1,000.00
$0.50 $0.13 $1,200.00 $5,000.00 $800.00 $1,000.00
$0.50 $0.32 $1,200.00 $5,000.00 $800.00 $1,000.00
$0.50 $0.16 $1,200.00 $5,000.00 $800.00 $1,000.00
$0.50 $0.03 $1,200.00 $5,000.00 $800.00 $1,000.00
$0.50 $0.07 $1,200.00 $5,000.00 $800.00 $1,000.00
$0.50 $0.15 $1,200.00 $5,000.00 $800.00 $1,000.00
$0.50 $1.02 $1,200.00 $5,000.00 $800.00 $1,000.00
$0.50 $0.63 $1,200.00 $5,000.00 $800.00 $1,000.00
Standardized Parts

Coffee Grinder-Cover Bottom Cap Gear Threaded Rod Nuts Semi-Tubular Rivet Fasteners
1014 1015 1016 1017 1018 1019 1020
$0.35 $0.16 $0.03 $0.07
0.19 0.111 0.02 0.046
1.29 1.29 1.29 1.29
0.3 0.1 0.1 0.1

$0.13 $0.13 $0.13 $0.13


25 25 25 25
200 200 200 200

$0.15 $0.13 $0.10 $0.10


30000 25000 20000 20000
500000 500000 500000 500000
2.5 2.5 2.5 2.5

$0.05 $0.05 $0.05 $0.05


200000 200000 200000 200000
200 200 200 200
5 5 5 5
1 1 1 1
1 1 1 1

$0.30 $0.30 $0.30 $0.30


60 60 60 60
200 200 200 200

$0.98 $0.76 $0.60 $0.64 0.0171 0.11319 0.6296

eakeven for 5000 parts


Fixed Cost Variable cost Sales Price/Part
$8,000.00 $0.53 $2.13
$8,000.00 $0.60 $2.20
$8,000.00 $0.60 $2.20
$8,000.00 $0.55 $2.15
$8,000.00 $0.56 $2.16
$8,000.00 $0.63 $2.23
$8,000.00 $0.52 $2.12
$8,000.00 $0.80 $2.40
$8,000.00 $0.51 $2.11
$8,000.00 $1.07 $2.67
$8,000.00 $0.50 $2.10
$8,000.00 $0.58 $2.18
$8,000.00 $0.63 $2.23
$8,000.00 $0.82 $2.42
$8,000.00 $0.66 $2.26
$8,000.00 $0.53 $2.13
$8,000.00 $0.57 $2.17
$8,000.00 $0.65 $2.25
$8,000.00 $1.52 $3.12
$8,000.00 $1.13 $2.73
Final Sales Price $45.96
Appendix E
DFA Cost Analysis - Redesign
Parameters Grinder Cap Handle U-connector Rubber Cover
Part: 1001 1003R 1004 1005
Cm $0.03 $0.19 $0.05 $0.07
m (weight) 0.02 0.13 0.03 0.024
cm (cost) 1.29 1.29 1.29 2.18
f ( fraction of waste) 0.1 0.1 0.2 0.2

Cl $0.13 $0.13 $0.13 $0.13


Cw ( hourly cost) 25 25 25 25
n' (production rate) 200 200 200 200

Ct $0.10 $0.38 $0.10 $0.13


ct (cost of tooling) 20000 75000 20000 25000
n ( entire production run) 500000 500000 500000 500000
k ( tooling wear factor) 2.5 2.5 2.5 2.5

Ce $0.05 $0.05 $0.05 $0.13


ce ( cost of capital equipment) 200000 200000 200000 500000
n' (production rate) 200 200 200 200
t_two (capital write off time (yrs) 5 5 5 5
L (load factor) 1 1 1 1
q ( fraction of equipment sharing between product) 1 1 1 1

Coh $0.30 $0.30 $0.30 $0.30


coh ( overhead hourly rate) 60 60 60 60
n' (production rate) 200 200 200 200

Total Cu per part $0.00 $0.60 $1.04 $0.62 $0.74

Total Cu $10.41

Order of Magnitude Estimate


Total part cost Mfg cost Price
1001 $0.031 $0.093 $0.279
1002 $0.000 $0.000 $0.000
1003R $0.184 $0.553 $1.660
1004 $0.046 $0.139 $0.418
1005 $0.063 $0.188 $0.565
1008R $0.493 $1.479 $4.437
1009 $0.011 $0.034 $0.102
1012 $0.000 $0.000 $0.000
1013 $0.128 $0.385 $1.156
1014R $1.417 $4.251 $12.754
1016 $0.028 $0.085 $0.255
1017 $0.065 $0.196 $0.587
1018 $0.154
1020 $0.630
Total $22.719
Collection Recaptacle Blade Inner Blade Piece
Coffee Grinder - UpperGear
Body Threaded Rod
1008R 1009 1013 1014R 1016 1017
$0.54 $0.01 $0.13 $1.56 $0.03 $0.07
0.294 0.008 0.083 0.845 0.02 0.046
1.29 1.29 1.29 1.29 1.29 1.29
0.3 0.1 0.2 0.3 0.1 0.1

$0.13 $0.13 $0.13 $0.13 $0.13 $0.13


25 25 25 25 25 25
200 200 200 200 200 200

$0.38 $0.20 $0.25 $0.50 $0.10 $0.10


75000 40000 50000 100000 20000 20000
500000 500000 500000 500000 500000 500000
2.5 2.5 2.5 2.5 2.5 2.5

$0.05 $0.05 $0.10 $0.05 $0.05 $0.05


200000 200000 400000 200000 200000 200000
200 200 200 200 200 200
5 5 5 5 5 5
1 1 1 1 1 1
1 1 1 1 1 1

$0.30 $0.30 $0.30 $0.30 $0.30 $0.30


60 60 60 60 60 60
200 200 200 200 200 200

$1.39 $0.69 $0.00 $0.91 $2.53 $0.60 $0.64

gnitude Estimate Manufacture Cost- Quote Comparison


Part No. Quote Estimate-Redesign Labor cost Material cost G&A
1001 $0.36 $0.50 $0.03 $1,200.00
1002 $0.00 $0.50 $0.00 $1,200.00
1003R $0.394 $0.50 $0.18 $1,200.00
1004 $0.197 $0.50 $0.05 $1,200.00
1005 $0.197 $0.50 $0.06 $1,200.00
1008R $0.363 $0.50 $0.49 $1,200.00
1009 $0.168 $0.50 $0.01 $1,200.00
1012 $0.000 $0.50 $0.00 $1,200.00
1013 $0.197 $0.50 $0.13 $1,200.00
1014R $1.880 $0.50 $1.42 $1,200.00
1016 $1.083 $0.50 $0.03 $1,200.00
1017 $0.421 $0.50 $0.07 $1,200.00
1018 $0.154 $0.50 $0.15 $1,200.00
1020 $0.630 $0.50 $0.63 $1,200.00
Total $6.045
Standardized Parts

Nuts Fasteners
1018 1020

0.0171 0.6296

Breakeven for 5000 parts


Depreciation Factory Expenses Sales and OH Fixed Cost Variable cost Sales Price/Part
$5,000.00 $800.00 $1,000.00 $8,000.00 $0.53 $2.13
$5,000.00 $800.00 $1,000.00 $8,000.00 $0.50 $2.10
$5,000.00 $800.00 $1,000.00 $8,000.00 $0.68 $2.28
$5,000.00 $800.00 $1,000.00 $8,000.00 $0.55 $2.15
$5,000.00 $800.00 $1,000.00 $8,000.00 $0.56 $2.16
$5,000.00 $800.00 $1,000.00 $8,000.00 $0.99 $2.59
$5,000.00 $800.00 $1,000.00 $8,000.00 $0.51 $2.11
$5,000.00 $800.00 $1,000.00 $8,000.00 $0.50 $2.10
$5,000.00 $800.00 $1,000.00 $8,000.00 $0.63 $2.23
$5,000.00 $800.00 $1,000.00 $8,000.00 $1.92 $3.52
$5,000.00 $800.00 $1,000.00 $8,000.00 $0.53 $2.13
$5,000.00 $800.00 $1,000.00 $8,000.00 $0.57 $2.17
$5,000.00 $800.00 $1,000.00 $8,000.00 $0.65 $2.25
$5,000.00 $800.00 $1,000.00 $8,000.00 $1.13 $2.73
Final Sales Price $30.52

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