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8 7 6 5 4 3 2 1 
A 
1 
4 
7 
9 
8 
6 
2 
11 
10 
3 
5 
5 
5 
DETAIL A 
NAME DATE 
11/21/2014 
MAGNETIC EGG 
CARRIAGE 
PARTS LIST 
M. E. C. M. E. C. 
NOTES: 
1. ALL LINKAGES AND CONNECTORS SYMMETRICAL 
ON EACH SIDE OF DOCKING STATION. 
2. APPLY LIQUID ADHESIVE (ITEM 12), FOR ALL 
INSTANCES OF INTERFACE BETWEEN 
- ITEM 6 AND ITEM 10 
- ITEM 7 AND ITEM 11 
- ITEM 4 AND ITEM 5 
- ITEM 1 AND ITEM 5. 
3. ITEM 5 SHOULD BE AS FLUSH AS POSSIBLE TO ITEM 1 
AND ITEM 4 RESPECTIVELY. 
ITEM NO. PART NUMBER DESCRIPTION QTY. 
1 DOCKING STATION 3D PRINTED PLA, 9.7" x 4.0" x 6.25" 1 
2 LINKAGE 1 3D PRINTED PLA, 0.125" THICK 2 
3 LINKAGE 2 3D PRINTED PLA, 0.125" THICK, 0.250" 
BOSS ON ONE END 2 
4 TRAY 3D PRINTED PLA, 10 EGG CAPACITY 
CONTAINER 1 
5 NEODYMIUM MAGNET 0.250" DiAMETER, 0.125" THICK 
CYLINDRICAL NEODYMIUM MAGNET 12 
6 OUTER CONNECTOR 1 3D PRINTED PLA, 0.200" LONG 2 
7 OUTER CONNECTOR 2 3D PRINTED PLA, 0.250" LONG 2 
8 OUTER CONNECTOR 3 3D PRINTED PLA, 0.450" LONG 2 
9 OUTER CONNECTOR 4 3D PRINTED PLA, 0.700" LONG 2 
10 INNER CONNECTOR 1 3D PRINTED PLA, 0.250" LONG 2 
11 INNER CONNECTOR 2 3D PRINTED PLA, 0.200" LONG 2 
12 LIQUID ADHESIVE PERMANENT ADHESIVE FOR PLA n/a 
D 
C 
B 
D 
C 
B 
UNLESS OTHERWISE SPECIFIED: 
DIMENSIONS ARE IN INCHES 
TOLERANCES: 
FRACTIONAL 
ANGULAR: MACH BEND 
TWO PLACE DECIMAL .010 
THREE PLACE DECIMAL .005 
INTERPRET GEOMETRIC 
TOLERANCING PER: 
MATERIAL 
DRAWN 
CHECKED 
ENG APPR. 
MFG APPR. 
Q.A. 
COMMENTS: 
TITLE: 
C. CHO 
A A 
NEXT ASSY USED ON 
APPLICATION 
APPLICATION 
THE INFORMATION CONTAINED IN THIS 
DRAWING IS THE SOLE PROPERTY OF 
CHRISTOPHER CHO. ANY REPRODUCTION 
IN PART OR AS A WHOLE WITHOUT THE 
WRITTEN PERMISSION OF CHRISTOPHER 
CHO IS PROHIBITED. 
FINISH 
SIZE B DWG. NO. REV 
SCALE: 1:2 WEIGHT: 
DO NOT SCALE DRAWING SHEET 1 OF 1 
8 7 6 5 4 3 2 1 
1A 
CHRISTOPHER CHO 
PROPRIETARY AND CONFIDENTIAL
8 7 6 5 4 3 2 1 
NAME DATE 
11/20/2014 
TITLE: 
MAGNETIC 
EGG CARRIAGE 
M. E. C. M. E. C. 
UNLESS OTHERWISE SPECIFIED: 
DIMENSIONS ARE IN INCHES 
TOLERANCES: 
FRACTIONAL 
ANGULAR: MACH BEND 
TWO PLACE DECIMAL .010 
THREE PLACE DECIMAL .005 
INTERPRET GEOMETRIC 
TOLERANCING PER: 
MATERIAL 
3D-PRINTED PLA 
D 
C 
B 
D 
C 
B 
DRAWN 
CHECKED 
ENG APPR. 
MFG APPR. 
Q.A. 
COMMENTS: 
C. CHO 
A A 
NEXT ASSY USED ON 
APPLICATION 
APPLICATION 
THE INFORMATION CONTAINED IN THIS 
DRAWING IS THE SOLE PROPERTY OF 
CHRISTOPHER CHO. ANY REPRODUCTION 
IN PART OR AS A WHOLE WITHOUT THE 
WRITTEN PERMISSION OF CHRISTOPHER 
CHO IS PROHIBITED. 
FINISH 
SIZE B DWG. NO. REV 
SCALE: 4:5 WEIGHT: 
DO NOT SCALE DRAWING SHEET 1 OF 7 
8 7 6 5 4 3 2 1 
1A 
CHRISTOPHER CHO 
PROPRIETARY AND CONFIDENTIAL
8 7 6 5 4 3 2 1 
DETAIL A 
(6.25) 
.125 
2x 
1.025 
1.000 
1.250 
3.050 
4.850 
6.650 
8.450 
.200 
2x 
.380 
.025 
2x 
1.150 
B 
9.70 
4.00 
2.50 
.375 
2x 
A 
R.75 
R.375±.010 
R.15 
5.500 
.250 
1.150 
.175 
1.925 
1.500 
.375 
1.125 
5.210 
.125 
2x 
.125 
3.650 
4.00 
R.125 
3x 
R.157 R2.000 .385 
NAME DATE 
11/20/2014 
DOCKING 
STATION 
M. E. C. M. E. C. 
UNLESS OTHERWISE SPECIFIED: 
DIMENSIONS ARE IN INCHES 
TOLERANCES: 
FRACTIONAL 
ANGULAR: MACH BEND 
TWO PLACE DECIMAL .010 
THREE PLACE DECIMAL .005 
INTERPRET GEOMETRIC 
TOLERANCING PER: 
MATERIAL 
3D-PRINTED PLA 
D 
C 
B 
D 
C 
B 
DRAWN 
CHECKED 
ENG APPR. 
MFG APPR. 
Q.A. 
COMMENTS: 
TITLE: 
C. CHO 
A A 
NEXT ASSY USED ON 
APPLICATION 
APPLICATION 
THE INFORMATION CONTAINED IN THIS 
DRAWING IS THE SOLE PROPERTY OF 
CHRISTOPHER CHO. ANY REPRODUCTION 
IN PART OR AS A WHOLE WITHOUT THE 
WRITTEN PERMISSION OF CHRISTOPHER 
CHO IS PROHIBITED. 
FINISH 
SIZE B DWG. NO. REV 
SCALE: 4:5 WEIGHT: 
DO NOT SCALE DRAWING SHEET 2 OF 7 
8 7 6 5 4 3 2 1 
1A 
CHRISTOPHER CHO 
PROPRIETARY AND CONFIDENTIAL
8 7 6 5 4 3 2 1 
1.939 
TO CENTERPOINT 
OF RADIUS 
5.803 
TO CENTERPOINT 
OF RADIUS 
2.150 
3.950 
5.750 
7.550 
.170 
3.843 
.250 
8x 
R.157 
8x 
.125 
.125 
DETAIL B 
SCALE 2 : 1 
NAME DATE 
11/20/2014 
DOCKING 
STATION 
M. E. C. M. E. C. 
UNLESS OTHERWISE SPECIFIED: 
DIMENSIONS ARE IN INCHES 
TOLERANCES: 
FRACTIONAL 
ANGULAR: MACH BEND 
TWO PLACE DECIMAL .010 
THREE PLACE DECIMAL .005 
INTERPRET GEOMETRIC 
TOLERANCING PER: 
MATERIAL 
3D-PRINTED PLA 
D 
C 
B 
D 
C 
B 
DRAWN 
CHECKED 
ENG APPR. 
MFG APPR. 
Q.A. 
COMMENTS: 
TITLE: 
C. CHO 
A A 
NEXT ASSY USED ON 
APPLICATION 
APPLICATION 
THE INFORMATION CONTAINED IN THIS 
DRAWING IS THE SOLE PROPERTY OF 
CHRISTOPHER CHO. ANY REPRODUCTION 
IN PART OR AS A WHOLE WITHOUT THE 
WRITTEN PERMISSION OF CHRISTOPHER 
CHO IS PROHIBITED. 
FINISH 
SIZE B DWG. NO. REV 
SCALE: 1:1 WEIGHT: 
DO NOT SCALE DRAWING SHEET 3 OF 7 
8 7 6 5 4 3 2 1 
1A 
CHRISTOPHER CHO 
PROPRIETARY AND CONFIDENTIAL
8 7 6 5 4 3 2 1 
NAME DATE 
11/20/2014 
UNLESS OTHERWISE SPECIFIED: 
DIMENSIONS ARE IN INCHES 
TOLERANCES: 
FRACTIONAL 
ANGULAR: MACH BEND 
TWO PLACE DECIMAL .010 
THREE PLACE DECIMAL .005 
INTERPRET GEOMETRIC 
TOLERANCING PER: 
MATERIAL 
DRAWN 
CHECKED 
ENG APPR. 
MFG APPR. 
Q.A. 
COMMENTS: 
TITLE: 
C. CHO 
M. E. C. M. E. C. TRAY 
3D-PRINTED PLA 
D 
C 
B 
D 
C 
B 
A A 
NEXT ASSY USED ON 
APPLICATION 
APPLICATION 
THE INFORMATION CONTAINED IN THIS 
DRAWING IS THE SOLE PROPERTY OF 
CHRISTOPHER CHO. ANY REPRODUCTION 
IN PART OR AS A WHOLE WITHOUT THE 
WRITTEN PERMISSION OF CHRISTOPHER 
CHO IS PROHIBITED. 
FINISH 
SIZE B DWG. NO. REV 
SCALE: 2:3 WEIGHT: 
DO NOT SCALE DRAWING SHEET 4 OF 7 
8 7 6 5 4 3 2 1 
1A 
CHRISTOPHER CHO 
PROPRIETARY AND CONFIDENTIAL
8 7 6 5 4 3 2 1 
NAME DATE 
11/20/2014 
LINKAGES 
LINKAGE 2 
M. E. C. M. E. C. 
UNLESS OTHERWISE SPECIFIED: 
DIMENSIONS ARE IN INCHES 
TOLERANCES: 
FRACTIONAL 
ANGULAR: MACH BEND 
TWO PLACE DECIMAL .010 
THREE PLACE DECIMAL .005 
INTERPRET GEOMETRIC 
TOLERANCING PER: 
MATERIAL 
3D-PRINTED PLA 
D 
C 
B 
D 
C 
B 
DRAWN 
CHECKED 
ENG APPR. 
MFG APPR. 
Q.A. 
COMMENTS: 
TITLE: 
C. CHO 
A A 
NEXT ASSY USED ON 
APPLICATION 
APPLICATION 
THE INFORMATION CONTAINED IN THIS 
DRAWING IS THE SOLE PROPERTY OF 
CHRISTOPHER CHO. ANY REPRODUCTION 
IN PART OR AS A WHOLE WITHOUT THE 
WRITTEN PERMISSION OF CHRISTOPHER 
CHO IS PROHIBITED. 
FINISH 
SIZE B DWG. NO. REV 
SCALE: 2:1 WEIGHT: 
DO NOT SCALE DRAWING SHEET 5 OF 7 
8 7 6 5 4 3 2 1 
1A 
CHRISTOPHER CHO 
PROPRIETARY AND CONFIDENTIAL
8 7 6 5 4 3 2 1 
INNER CONNECTOR 1 INNER CONNECTOR 2 
.075 
TYP 
.25 
.050 
TYP 
.200 
TYP 
.20 
NAME DATE 
11/20/2014 
INNER 
CONNECTORS 
M. E. C. M. E. C. 
UNLESS OTHERWISE SPECIFIED: 
DIMENSIONS ARE IN INCHES 
TOLERANCES: 
FRACTIONAL 
ANGULAR: MACH BEND 
TWO PLACE DECIMAL .010 
THREE PLACE DECIMAL .005 
INTERPRET GEOMETRIC 
TOLERANCING PER: 
MATERIAL 
3D-PRINTED PLA 
D 
C 
B 
D 
C 
B 
DRAWN 
CHECKED 
ENG APPR. 
MFG APPR. 
Q.A. 
COMMENTS: 
TITLE: 
C. CHO 
A A 
NEXT ASSY USED ON 
APPLICATION 
APPLICATION 
THE INFORMATION CONTAINED IN THIS 
DRAWING IS THE SOLE PROPERTY OF 
CHRISTOPHER CHO. ANY REPRODUCTION 
IN PART OR AS A WHOLE WITHOUT THE 
WRITTEN PERMISSION OF CHRISTOPHER 
CHO IS PROHIBITED. 
FINISH 
SIZE B DWG. NO. REV 
SCALE: 8:1 WEIGHT: 
DO NOT SCALE DRAWING SHEET 6 OF 7 
8 7 6 5 4 3 2 1 
1A 
CHRISTOPHER CHO 
PROPRIETARY AND CONFIDENTIAL
8 7 6 5 4 3 2 1 
Outer Connector 4 Outer Connector 3 Outer Connector 2 
.075 
TYP 
.25 .20 
.125 
TYP 
.45 
.05 
TYP 
.20 
TYP 
.70 
NAME DATE 
11/20/2014 
OUTER 
CONNECTORS 
Outer Connector 1 
M. E. C. M. E. C. 
UNLESS OTHERWISE SPECIFIED: 
DIMENSIONS ARE IN INCHES 
TOLERANCES: 
FRACTIONAL 
ANGULAR: MACH BEND 
TWO PLACE DECIMAL .010 
THREE PLACE DECIMAL .005 
INTERPRET GEOMETRIC 
TOLERANCING PER: 
MATERIAL 
3D-PRINTED PLA 
D 
C 
B 
D 
C 
B 
DRAWN 
CHECKED 
ENG APPR. 
MFG APPR. 
Q.A. 
COMMENTS: 
TITLE: 
C. CHO 
A A 
NEXT ASSY USED ON 
APPLICATION 
APPLICATION 
THE INFORMATION CONTAINED IN THIS 
DRAWING IS THE SOLE PROPERTY OF 
CHRISTOPHER CHO. ANY REPRODUCTION 
IN PART OR AS A WHOLE WITHOUT THE 
WRITTEN PERMISSION OF CHRISTOPHER 
CHO IS PROHIBITED. 
FINISH 
SIZE B DWG. NO. REV 
SCALE: 6:1 WEIGHT: 
DO NOT SCALE DRAWING SHEET 7 OF 7 
8 7 6 5 4 3 2 1 
1A 
CHRISTOPHER CHO 
PROPRIETARY AND CONFIDENTIAL
Magnetic 
Egg Carriage 
Design and Engineering 
Analysis Report 
Christopher Cho 
November 20, 2014 
FirstBuild – Icebox Challenge
P a g e | 1 
C. CHO, FirstBuild 
11/20/2014 
FirstBuild 
Icebox Challenge 
Applicant: Christopher Cho 
Design Submission: Magnetic Egg Carriage 
Date of Submission: November 20, 2014 
Content: Design and Engineering Analysis Report 
Requirements 
 Designs must be able to be printed in a MakerBot Replicator (5th generation). The build 
volume of the printer is 9.9L x 7.8W x 5.9H in 
Guidelines 
 Ideas could range from purely 3D printed pieces to battery operated electromechanical 
devices 
 Designs/solutions should serve their function inside of the refrigerator 
 We encourage entries also be submitted to the Thingiverse site with the tag 
#IceboxChallenge for a chance to be featured on their site. 
Deliverable Views 
 Front View 
 Side View 
 Top View 
 Optional Additional View (3x) 
Additional Deliverables 
 A CAD file must be submitted, preferably STL.
P a g e | 2 
C. CHO, FirstBuild 
11/20/2014 
Design Considerations 
Function 
The Egg Carriage is a carton-like tray that hangs under a shelf on the refrigerator door. 
The tray is attached to a dock via linkages and magnets; the dock itself is secured to the shelf 
above via rigid arms. Utilization is simple and intuitive: 
In the “Away” position, the tray is magnetically secured directly under the dock, which, by 
design, is neatly placed under the shelf. This placement allows storage and protection for the 
eggs. 
In the “Forward” position, the linkages swing out and the tray is magnetically secured to the 
forward set of magnets. In this position, the tray presents itself for use. 
Image 1: Away Position Image 2: Forward Position 
Image 3: Away Position Image 4: Forward Position
P a g e | 3 
Image 6: Forward Position 
C. CHO, FirstBuild 
11/20/2014 
Image 5: Away Position
P a g e | 4 
C. CHO, FirstBuild 
11/20/2014 
Fabrication 
All the components of the Egg Carriage can be fabricated via 3D printer save the 
neodymium magnets. These essential magnets cannot be fabricated in the same manner and 
must be purchased from a third-party. Though not included, some of the components, such as 
the hanging arm-hooks on the dock, may need support material to create. 
It may be important to mention that this may require a minimum of 3 separate print runs, as 
the dock and tray will likely require separate print runs. However, the final print run can 
likely fabricate the remaining loose components (linkages/connectors) in one go. 
Attached as well are CAD drawings in the case that injection molding or CNC machining is 
preferred. 
Design Justification 
The intent of this design was to target and eliminate the large footprint of egg storage. 
Given their fragile nature, the simplest way for refrigerator manufacturers to ensure security 
was to dedicate an area specifically for eggs. Sadly, this usually resulted in a siphoned off and 
dedicated “egg-only” zone that took up quite a bit of surface area. I saw this as a challenge to 
get these eggs out of the way while still maintaining their integrity. 
The result of my efforts was the Egg Carriage that you can visualize using the attached 
models and drawings. I kept the tried-and-true egg carton design, but targeted the location 
instead. The Egg Carriage allows a refrigerator owner to simply hang their eggs off of a shelf 
on their refrigerator door and recover all the lost space that was once a dedicated “egg-only” 
zone. 
This concept may seem daunting at first; why would one risk such fragile cargo with a 
dynamic container that hangs? After much design iteration, I was able to develop a secure 
method to keep the eggs intact, but still easily accessible. The strength of neodymium 
magnets has been undervalued and underused for quite some time, and I feel that their 
incorporation here allows for a strong, yet aesthetically pleasing design. Their hidden 
adhesive strength removes the need for awkwardly placed securing mechanisms like locks or 
latches. 
The question then remains of whether or not the structural integrity of the material can 
withstand its own weight with cargo. These issues are addressed below in the Weight and 
Stress Analysis portion of this report.
P a g e | 5 
C. CHO, FirstBuild 
11/20/2014 
Cost Analysis 
The total build volume of all the components that need to be 3D printed is 544.22 cm3, or 
33.207 in3. Utilizing Makerbot’s proprietary PLA white filament at $48.00 per 0.9 kilograms, 
the cost of the prints can be approximated (excludes support material). 
Total Build Volume 544.23 cm3 (33.207 in3) 
3D Printed PLA Filament Density[1] 1.25 g/cm3 (0.045 lbs/in3) 
Filament Cost[2] $48/0.9 kg ($48/1.984 lbs) 
Neodymium Magnet Cost[3] $0.34 
Quantity of Magnets 8 
Table 1: Cost Analysis of Components 
[ 
⁄ ( 
⁄ ) 
⁄ ] ( ) 
Note: Cost does not include shipping and other acquisition expenses. 
Potential Improvements 
Over the development of this idea, there were many improvements that could have been 
made, many of which were stifled by cost or design size criteria. The simplest way to upgrade 
the design would be to utilize an adhesive (i.e. command strips, Velcro strips, etc.) that would 
adhere the bottom of the shelf to the top of the dock. This would negate the deflection in the 
rigid arms and really solidify the unit to the door of the refrigerator. Unfortunately, this would 
remove the possibility of sliding the Egg Carriage back and forth to dynamically adjust space 
on demand. 
The most glaring detail of this design is the capacity for only 10 eggs, rather than the standard 
dozen. Due to the static sizes of most eggs, it was not possible to create a tray of this design 
that held the remaining two without exceeding the length restriction (9.9 inches) of this 
challenge. However, part of the design intent was to include the potential for unbridled 
expandability along that length if one were to have access to a 3D printer with a larger 
workable area. 
One of the unofficial challenge guidelines was to make it fit my refrigerator. However, for 
consumer product design, there is no such concept. That is where modularity and universality 
come into play. The rigid arms that hang on to the Egg Carriage are a static height that allows 
the Egg Carriage to be placed neatly underneath the shelf. However, with telescoping arms 
and a locking mechanism, one could have a dynamic length that can be adjusted for any 
consumer’s refrigerator.
P a g e | 6 
Another possible, but minor, improvement would be to increase the size of the magnets. 
Neodymium magnets are strong, but their pull-force is still proportionate to their size; a larger 
diameter or thickness would allow for a better factor of safety. Because neodymium magnets 
are graded, with the utilized N42 being of a lower end, a higher grade magnet will also yield a 
larger pull-force. 
My final suggestion for design improvements would be full incorporation onto a refrigerator 
door. This means that the docking system is molded with the rest of the door at the 
manufacturing stage for a flush, clean design; the tray would simply click onto the door itself. 
The elimination of the hanging arms will allow a skeptical consumer to accept the “my eggs 
are simply dangling there?” concept with much more relief. This static design does come with 
downsides in terms of mobility, but a huge boost in rigidity and aesthetic. 
At $39 per unit, this design is a little more on the pricy side. To allow it to be a little 
C. CHO, FirstBuild 
11/20/2014 
more economical, some compromises can be made regarding material and design. 
Seeing as the material is 93% of the cost, one can definitely make changes to where the 
filament is supplied. However, the MakerBot Replicator (5th Generation) is only designed to 
spool proprietary filament without modifications. When comparing with prices from third 
party suppliers, filament at 40-60% of the original cost will directly correlate with 40-60% 
reduced cost when fabricating the Egg Carriage. For a volumetrically large print such as this, 
it may be cost effective to make modifications for the MakerBot to accept non-proprietary 
filament, or print on a less restrictive machine. 
The other option to reduce overall cost is to cut corners on the design itself. Optimization of 
material usage will trade structural rigidity for price, however, that degree of optimization 
extends beyond the scope of this report.
P a g e | 7 
C. CHO, FirstBuild 
11/20/2014 
Weight Analysis 
Name Quantity Volume (cm3, in3) Material Weight (g, lbs) 
Tra y 1 242.26 (14.78) ABS P lastic 302.83 (0 .66763) 
Dock 1 297.93 (18.18) ABS Plastic 372.41 (0.82102) 
Linkage 1 2 2.045 (0.125) ABS Plastic 2.556 (0.00564) 
Linkage 2 2 1.643 (0.100) ABS Plastic 2.054 (0.00453) 
Outer Connector 1 2 0.049 (0.003) ABS Plastic 0.061 (0.00013) 
Outer Connector 2 2 0.043 (0.003) ABS Plastic 0.054 (0.00012) 
Outer Connector 3 2 0.075 (0.005) ABS Plastic 0.094 (0.00021) 
Outer Connector 4 2 0.107 (0.007) ABS Plastic 0.134 (0.00030) 
Inner Connector 1 2 0.035 (0.002) ABS Plastic 0.044 (0.00010) 
Inner Connector 2 2 0.032 (0.002) ABS Plastic 0.040 (0.00009) 
Neodymium Magnet 8 0.101 (0.006) NdFeB 0.752 (0.00166) 
Eggs 10 - - 1380.00 (3.04200) 
Total with Eggs - - - 2061.03 (4.5421) 
Total without Eggs - 544.32 (33.216) - 681.03 (1.5014) 
Table 2: Bill of Materials; refer to separate Parts List for component representation 
Average Weight of Extra Large Egg[4] 63 ~ 69 g (0.139 ~ 0.152 lbs) 
Maximum Egg Capacity 10 eggs 
Factor of Safety 2 
Table 3: Weight Analysis of Eggs 
[ ] 
( ) 
Average Volume of Neodymium Magnets 0.101 cm3 (0.006 in3) 
Density of Neodymium Magnets[5] 7.45 g/cm3 (0.269 lbs/in3) 
Number of Magnets in Tray 4 pieces 
Factor of Safety 2 
Table 4: Weight Analysis of Magnets 
[ 
⁄ ] 
( )
P a g e | 8 
C. CHO, FirstBuild 
11/20/2014 
Volume of Tray 242.26 cm3 (14.78 in3) 
Volume of Linkages 7.38 cm3 (0.44 in3) 
Volume of Connectors 0.682 cm3 (0.044 in3) 
3D Printed PLA Filament Density[1] 1.25 g/cm3 (0.045 lbs/in3) 
3D Printed ABS Filament Density[1] 1.04 g/cm3 (0.038 lbs/in3) 
Factor of Safety 2 
Table 5: Weight Analysis of 3D Printed Components 
[[ ] 
⁄ ] 
( ) 
( ) 
Design Strength 2011.83 g (4.435 lbs) 
Magnetic Pull Force[6]: 
- Magnet to Magnet Contact 
- Grade N42 Neodymium 
- 0.250” Diameter 
- 0.125” Thickness 
1043.26 g (2.30 lbs) 
Magnet Count 4 pieces 
Table 6: Pull-Force Analysis of Magnets 
( ) 
Conclusion 
Based on the calculations above, the combined pull force of the Neodymium magnets 
(9.2 pounds) far exceeds the weight of the tray, linkages, connectors, as well as a maximum 
capacity of eggs combined (4.435 pounds), inclusive of the factor of safety. With these 
calculations, this choice of magnets allows a safety factor of 4. If a factor of safety higher 
than this is desired, a higher grade of Neodymium magnets may be considered, as well as an 
increase in the size of the magnets used. It is also possible to further maximize the factor of 
safety by optimizing the conservancy of material when printing the tray.
P a g e | 9 
C. CHO, FirstBuild 
11/20/2014 
Stress Analysis 
Connectors 
The bulk of the forces that will be applied to the egg tray itself will be the downward 
forces of gravity. Based on the rigidity and tighter tolerances in the axial direction of the 
connectors, it can be assumed that the forces axial to the connectors can be neglected. When 
in changing state between forward and backward positioning, the majority of the stress will lie 
with the connectors that hold the linkages together, and hold the linkages to the tray and dock. 
Due to the symmetrical nature of the connector, the stress can be modeled as unidirectional in 
the transverse direction. 
Image 7: 20 lbf of transverse load on Outer Connector 4 
Image 8: 20 lbf of transverse load on Outer Connector 2
P a g e | 10 
The deformation analyses were performed on the Outer Connector 4 and Outer Connector 
2 components because they were the longest and shortest in length, respectively. This 
characteristic, combined with the consistent diameters across all the connectors, allows us to 
visualize the range of maximum deformations for different lengths of connectors. Not only 
are the simulated deformations on the magnitude of 1/1000th of an inch, but these are also 
conservative estimates. 
In practical application, some of these connectors would be reinforced by their 
complementing Inner Connector components. These solid Inner Connectors would be 
inserted into the recess of the Outer Connectors, effectively creating a solid cylinder. The 
bending moment for a solid cylinder is much higher than that of a hollow cylinder, greatly 
increasing their ability to withstand deformation. Utilizing a 20 pound-force load was quite 
safe as well, considering the maximum weight of a full egg tray was calculated to be 3.721 
pounds. Even if one were to accidentally bump or mishandle the egg carriage during use, the 
magnets and tight tolerance of the linkage/connectors would keep the cargo intact, while the 
strength of the connectors would not allow the rigidity of the system to collapse. 
Analysis of the linkages themselves was deemed unnecessary, as their presence merely 
represents a guide for the motions of the tray. The forces exerted on the system that maintains 
the tray preside mainly with the connectors’ rigidity and the pull-force of the neodymium 
magnets. 
C. CHO, FirstBuild 
11/20/2014 
Arms 
One of the design intents was to eliminate the need for an excessive footprint to store 
eggs. Given their fragile nature, a secure environment must be enforced. As the entire 
structure is hanging off of the shelf’s “fence”, the arms that secure the unit must be able to 
withstand the maximum weight of the egg carriage with a factor of safety. 
Image 9: Displacement from 20 lbf of downwards-facing load on the Tray
P a g e | 11 
C. CHO, FirstBuild 
11/20/2014 
Image 10: Displacement from a 20 lbf of downwards-facing load on the Tray (view from other side) 
Given that the weight of a full capacity Egg Carriage is projected to be 4.542 pounds, the 
arms must be able to withstand that force with minimal deflection. Given the positioning of 
the carriage, it is unlikely that any kind of accidental bumping or knocking will apply a 
downwards force on the carriage itself; it is more likely for the hooks themselves to absorb 
any such impacts. Thus, only the weight of the tray and its cargo was considered as 
contributing factors in this simulation. 
As seen in the displacement results from an applied 20 pound force (safety factor of 5), the 
front and back of the arms receive minimal change in position, with the blue to light blue 
color labels signifying a ranging displacement from 4.000 x 10-32 in to 0.200 in, respectively. 
The displacements near the back of the unit are larger, but an expected phenomenon due to the 
nature of the carriage’s shape. Potential solutions to resolve this minor issue was presented 
previously under Design Considerations, Potential Improvements. 
In the realm of permanent deformation or potential fracture, the theoretical maximum 
deformation can be calculated. 
Uniform gravitational force over the area can be summed into one 
resultant vector at the center of gravity. The moment is uniform 
along the beam in question because the distance from the force 
vector and then centroid of the beam is constant. 
Image 11: Force Vector Diagram
P a g e | 12 
Image 12: Dimensions of Cross Section and Center of Gravity (inches) Image 13: Dimension to Pivot Point (inches) 
C. CHO, FirstBuild 
11/20/2014 
Elastic Modulus of 3D Printed PLA[7] 3368 MPa (488487 psi) 
Applied Force 20 lbs (9071.85 g) 
Distance to Center of Gravity 2 in (50.80 mm) 
Length of Assumed Cantilever 4 in (101.60 mm) 
Cross-Sectional Base 0.375 in (9.53 mm) 
Cross-Sectional Height 0.375 in (9.53 mm) 
Table 7: Stress Analysis of “Cantilever” Arms 
( ) 
( 
) 
( )( ) 
( 
⁄ ) [ 
( )( ) 
] 
The max deflection of the hanging arm will be almost 1/10th of an inch at the point where the 
arm meets the main body of the dock. However, this is for an extremely conservative 20 
pound force analysis. Given that these equations are linear, the max weight of the entire 
assembly is a little less than 5 pounds, so the practical maximum deflection at that point will be 
a quarter of this value, or 0.025 inches.
P a g e | 13 
From the simulated stress image below, the stress is maximum near the point previously 
calculated, but is limited to only 2906 psi and at no risk of fracture due to the material’s high 
rigidity[8]. 
C. CHO, FirstBuild 
11/20/2014 
Image 14: Stress from 20 lbf of downwards-facing load on the Tray
P a g e | 14 
C. CHO, FirstBuild 
11/20/2014 
References 
[1]http://www.toybuilderlabs.com/blogs/news/13053117-filament-volume-and-length 
[2]http://store.makerbot.com/pla-filament#rep-truewhite 
[3]http://www.kjmagnetics.com/proddetail.asp?prod=D42E 
[4]http://www.fsis.usda.gov/wps/portal/fsis/topics/food-safety-education/get-answers/food-safety- 
fact-sheets/egg-products-preparation/shell-eggs-from-farm-to-table/#17 
[5]https://www.kjmagnetics.com/specs.asp 
[6]https://www.kjmagnetics.com/calculator.asp 
[7]https://www.academia.edu/6209168/Mechanical_properties_of_components_fabricated_with 
_open-source_3-D_printers_under_realistic_environmental_conditions 
[8]http://bme.ucdavis.edu/team/equipment/3d-printer-comparison/

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Magnetic Egg Carriage

  • 1. 8 7 6 5 4 3 2 1 A 1 4 7 9 8 6 2 11 10 3 5 5 5 DETAIL A NAME DATE 11/21/2014 MAGNETIC EGG CARRIAGE PARTS LIST M. E. C. M. E. C. NOTES: 1. ALL LINKAGES AND CONNECTORS SYMMETRICAL ON EACH SIDE OF DOCKING STATION. 2. APPLY LIQUID ADHESIVE (ITEM 12), FOR ALL INSTANCES OF INTERFACE BETWEEN - ITEM 6 AND ITEM 10 - ITEM 7 AND ITEM 11 - ITEM 4 AND ITEM 5 - ITEM 1 AND ITEM 5. 3. ITEM 5 SHOULD BE AS FLUSH AS POSSIBLE TO ITEM 1 AND ITEM 4 RESPECTIVELY. ITEM NO. PART NUMBER DESCRIPTION QTY. 1 DOCKING STATION 3D PRINTED PLA, 9.7" x 4.0" x 6.25" 1 2 LINKAGE 1 3D PRINTED PLA, 0.125" THICK 2 3 LINKAGE 2 3D PRINTED PLA, 0.125" THICK, 0.250" BOSS ON ONE END 2 4 TRAY 3D PRINTED PLA, 10 EGG CAPACITY CONTAINER 1 5 NEODYMIUM MAGNET 0.250" DiAMETER, 0.125" THICK CYLINDRICAL NEODYMIUM MAGNET 12 6 OUTER CONNECTOR 1 3D PRINTED PLA, 0.200" LONG 2 7 OUTER CONNECTOR 2 3D PRINTED PLA, 0.250" LONG 2 8 OUTER CONNECTOR 3 3D PRINTED PLA, 0.450" LONG 2 9 OUTER CONNECTOR 4 3D PRINTED PLA, 0.700" LONG 2 10 INNER CONNECTOR 1 3D PRINTED PLA, 0.250" LONG 2 11 INNER CONNECTOR 2 3D PRINTED PLA, 0.200" LONG 2 12 LIQUID ADHESIVE PERMANENT ADHESIVE FOR PLA n/a D C B D C B UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL ANGULAR: MACH BEND TWO PLACE DECIMAL .010 THREE PLACE DECIMAL .005 INTERPRET GEOMETRIC TOLERANCING PER: MATERIAL DRAWN CHECKED ENG APPR. MFG APPR. Q.A. COMMENTS: TITLE: C. CHO A A NEXT ASSY USED ON APPLICATION APPLICATION THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF CHRISTOPHER CHO. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF CHRISTOPHER CHO IS PROHIBITED. FINISH SIZE B DWG. NO. REV SCALE: 1:2 WEIGHT: DO NOT SCALE DRAWING SHEET 1 OF 1 8 7 6 5 4 3 2 1 1A CHRISTOPHER CHO PROPRIETARY AND CONFIDENTIAL
  • 2. 8 7 6 5 4 3 2 1 NAME DATE 11/20/2014 TITLE: MAGNETIC EGG CARRIAGE M. E. C. M. E. C. UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL ANGULAR: MACH BEND TWO PLACE DECIMAL .010 THREE PLACE DECIMAL .005 INTERPRET GEOMETRIC TOLERANCING PER: MATERIAL 3D-PRINTED PLA D C B D C B DRAWN CHECKED ENG APPR. MFG APPR. Q.A. COMMENTS: C. CHO A A NEXT ASSY USED ON APPLICATION APPLICATION THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF CHRISTOPHER CHO. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF CHRISTOPHER CHO IS PROHIBITED. FINISH SIZE B DWG. NO. REV SCALE: 4:5 WEIGHT: DO NOT SCALE DRAWING SHEET 1 OF 7 8 7 6 5 4 3 2 1 1A CHRISTOPHER CHO PROPRIETARY AND CONFIDENTIAL
  • 3. 8 7 6 5 4 3 2 1 DETAIL A (6.25) .125 2x 1.025 1.000 1.250 3.050 4.850 6.650 8.450 .200 2x .380 .025 2x 1.150 B 9.70 4.00 2.50 .375 2x A R.75 R.375±.010 R.15 5.500 .250 1.150 .175 1.925 1.500 .375 1.125 5.210 .125 2x .125 3.650 4.00 R.125 3x R.157 R2.000 .385 NAME DATE 11/20/2014 DOCKING STATION M. E. C. M. E. C. UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL ANGULAR: MACH BEND TWO PLACE DECIMAL .010 THREE PLACE DECIMAL .005 INTERPRET GEOMETRIC TOLERANCING PER: MATERIAL 3D-PRINTED PLA D C B D C B DRAWN CHECKED ENG APPR. MFG APPR. Q.A. COMMENTS: TITLE: C. CHO A A NEXT ASSY USED ON APPLICATION APPLICATION THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF CHRISTOPHER CHO. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF CHRISTOPHER CHO IS PROHIBITED. FINISH SIZE B DWG. NO. REV SCALE: 4:5 WEIGHT: DO NOT SCALE DRAWING SHEET 2 OF 7 8 7 6 5 4 3 2 1 1A CHRISTOPHER CHO PROPRIETARY AND CONFIDENTIAL
  • 4. 8 7 6 5 4 3 2 1 1.939 TO CENTERPOINT OF RADIUS 5.803 TO CENTERPOINT OF RADIUS 2.150 3.950 5.750 7.550 .170 3.843 .250 8x R.157 8x .125 .125 DETAIL B SCALE 2 : 1 NAME DATE 11/20/2014 DOCKING STATION M. E. C. M. E. C. UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL ANGULAR: MACH BEND TWO PLACE DECIMAL .010 THREE PLACE DECIMAL .005 INTERPRET GEOMETRIC TOLERANCING PER: MATERIAL 3D-PRINTED PLA D C B D C B DRAWN CHECKED ENG APPR. MFG APPR. Q.A. COMMENTS: TITLE: C. CHO A A NEXT ASSY USED ON APPLICATION APPLICATION THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF CHRISTOPHER CHO. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF CHRISTOPHER CHO IS PROHIBITED. FINISH SIZE B DWG. NO. REV SCALE: 1:1 WEIGHT: DO NOT SCALE DRAWING SHEET 3 OF 7 8 7 6 5 4 3 2 1 1A CHRISTOPHER CHO PROPRIETARY AND CONFIDENTIAL
  • 5. 8 7 6 5 4 3 2 1 NAME DATE 11/20/2014 UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL ANGULAR: MACH BEND TWO PLACE DECIMAL .010 THREE PLACE DECIMAL .005 INTERPRET GEOMETRIC TOLERANCING PER: MATERIAL DRAWN CHECKED ENG APPR. MFG APPR. Q.A. COMMENTS: TITLE: C. CHO M. E. C. M. E. C. TRAY 3D-PRINTED PLA D C B D C B A A NEXT ASSY USED ON APPLICATION APPLICATION THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF CHRISTOPHER CHO. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF CHRISTOPHER CHO IS PROHIBITED. FINISH SIZE B DWG. NO. REV SCALE: 2:3 WEIGHT: DO NOT SCALE DRAWING SHEET 4 OF 7 8 7 6 5 4 3 2 1 1A CHRISTOPHER CHO PROPRIETARY AND CONFIDENTIAL
  • 6. 8 7 6 5 4 3 2 1 NAME DATE 11/20/2014 LINKAGES LINKAGE 2 M. E. C. M. E. C. UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL ANGULAR: MACH BEND TWO PLACE DECIMAL .010 THREE PLACE DECIMAL .005 INTERPRET GEOMETRIC TOLERANCING PER: MATERIAL 3D-PRINTED PLA D C B D C B DRAWN CHECKED ENG APPR. MFG APPR. Q.A. COMMENTS: TITLE: C. CHO A A NEXT ASSY USED ON APPLICATION APPLICATION THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF CHRISTOPHER CHO. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF CHRISTOPHER CHO IS PROHIBITED. FINISH SIZE B DWG. NO. REV SCALE: 2:1 WEIGHT: DO NOT SCALE DRAWING SHEET 5 OF 7 8 7 6 5 4 3 2 1 1A CHRISTOPHER CHO PROPRIETARY AND CONFIDENTIAL
  • 7. 8 7 6 5 4 3 2 1 INNER CONNECTOR 1 INNER CONNECTOR 2 .075 TYP .25 .050 TYP .200 TYP .20 NAME DATE 11/20/2014 INNER CONNECTORS M. E. C. M. E. C. UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL ANGULAR: MACH BEND TWO PLACE DECIMAL .010 THREE PLACE DECIMAL .005 INTERPRET GEOMETRIC TOLERANCING PER: MATERIAL 3D-PRINTED PLA D C B D C B DRAWN CHECKED ENG APPR. MFG APPR. Q.A. COMMENTS: TITLE: C. CHO A A NEXT ASSY USED ON APPLICATION APPLICATION THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF CHRISTOPHER CHO. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF CHRISTOPHER CHO IS PROHIBITED. FINISH SIZE B DWG. NO. REV SCALE: 8:1 WEIGHT: DO NOT SCALE DRAWING SHEET 6 OF 7 8 7 6 5 4 3 2 1 1A CHRISTOPHER CHO PROPRIETARY AND CONFIDENTIAL
  • 8. 8 7 6 5 4 3 2 1 Outer Connector 4 Outer Connector 3 Outer Connector 2 .075 TYP .25 .20 .125 TYP .45 .05 TYP .20 TYP .70 NAME DATE 11/20/2014 OUTER CONNECTORS Outer Connector 1 M. E. C. M. E. C. UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL ANGULAR: MACH BEND TWO PLACE DECIMAL .010 THREE PLACE DECIMAL .005 INTERPRET GEOMETRIC TOLERANCING PER: MATERIAL 3D-PRINTED PLA D C B D C B DRAWN CHECKED ENG APPR. MFG APPR. Q.A. COMMENTS: TITLE: C. CHO A A NEXT ASSY USED ON APPLICATION APPLICATION THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF CHRISTOPHER CHO. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF CHRISTOPHER CHO IS PROHIBITED. FINISH SIZE B DWG. NO. REV SCALE: 6:1 WEIGHT: DO NOT SCALE DRAWING SHEET 7 OF 7 8 7 6 5 4 3 2 1 1A CHRISTOPHER CHO PROPRIETARY AND CONFIDENTIAL
  • 9. Magnetic Egg Carriage Design and Engineering Analysis Report Christopher Cho November 20, 2014 FirstBuild – Icebox Challenge
  • 10. P a g e | 1 C. CHO, FirstBuild 11/20/2014 FirstBuild Icebox Challenge Applicant: Christopher Cho Design Submission: Magnetic Egg Carriage Date of Submission: November 20, 2014 Content: Design and Engineering Analysis Report Requirements  Designs must be able to be printed in a MakerBot Replicator (5th generation). The build volume of the printer is 9.9L x 7.8W x 5.9H in Guidelines  Ideas could range from purely 3D printed pieces to battery operated electromechanical devices  Designs/solutions should serve their function inside of the refrigerator  We encourage entries also be submitted to the Thingiverse site with the tag #IceboxChallenge for a chance to be featured on their site. Deliverable Views  Front View  Side View  Top View  Optional Additional View (3x) Additional Deliverables  A CAD file must be submitted, preferably STL.
  • 11. P a g e | 2 C. CHO, FirstBuild 11/20/2014 Design Considerations Function The Egg Carriage is a carton-like tray that hangs under a shelf on the refrigerator door. The tray is attached to a dock via linkages and magnets; the dock itself is secured to the shelf above via rigid arms. Utilization is simple and intuitive: In the “Away” position, the tray is magnetically secured directly under the dock, which, by design, is neatly placed under the shelf. This placement allows storage and protection for the eggs. In the “Forward” position, the linkages swing out and the tray is magnetically secured to the forward set of magnets. In this position, the tray presents itself for use. Image 1: Away Position Image 2: Forward Position Image 3: Away Position Image 4: Forward Position
  • 12. P a g e | 3 Image 6: Forward Position C. CHO, FirstBuild 11/20/2014 Image 5: Away Position
  • 13. P a g e | 4 C. CHO, FirstBuild 11/20/2014 Fabrication All the components of the Egg Carriage can be fabricated via 3D printer save the neodymium magnets. These essential magnets cannot be fabricated in the same manner and must be purchased from a third-party. Though not included, some of the components, such as the hanging arm-hooks on the dock, may need support material to create. It may be important to mention that this may require a minimum of 3 separate print runs, as the dock and tray will likely require separate print runs. However, the final print run can likely fabricate the remaining loose components (linkages/connectors) in one go. Attached as well are CAD drawings in the case that injection molding or CNC machining is preferred. Design Justification The intent of this design was to target and eliminate the large footprint of egg storage. Given their fragile nature, the simplest way for refrigerator manufacturers to ensure security was to dedicate an area specifically for eggs. Sadly, this usually resulted in a siphoned off and dedicated “egg-only” zone that took up quite a bit of surface area. I saw this as a challenge to get these eggs out of the way while still maintaining their integrity. The result of my efforts was the Egg Carriage that you can visualize using the attached models and drawings. I kept the tried-and-true egg carton design, but targeted the location instead. The Egg Carriage allows a refrigerator owner to simply hang their eggs off of a shelf on their refrigerator door and recover all the lost space that was once a dedicated “egg-only” zone. This concept may seem daunting at first; why would one risk such fragile cargo with a dynamic container that hangs? After much design iteration, I was able to develop a secure method to keep the eggs intact, but still easily accessible. The strength of neodymium magnets has been undervalued and underused for quite some time, and I feel that their incorporation here allows for a strong, yet aesthetically pleasing design. Their hidden adhesive strength removes the need for awkwardly placed securing mechanisms like locks or latches. The question then remains of whether or not the structural integrity of the material can withstand its own weight with cargo. These issues are addressed below in the Weight and Stress Analysis portion of this report.
  • 14. P a g e | 5 C. CHO, FirstBuild 11/20/2014 Cost Analysis The total build volume of all the components that need to be 3D printed is 544.22 cm3, or 33.207 in3. Utilizing Makerbot’s proprietary PLA white filament at $48.00 per 0.9 kilograms, the cost of the prints can be approximated (excludes support material). Total Build Volume 544.23 cm3 (33.207 in3) 3D Printed PLA Filament Density[1] 1.25 g/cm3 (0.045 lbs/in3) Filament Cost[2] $48/0.9 kg ($48/1.984 lbs) Neodymium Magnet Cost[3] $0.34 Quantity of Magnets 8 Table 1: Cost Analysis of Components [ ⁄ ( ⁄ ) ⁄ ] ( ) Note: Cost does not include shipping and other acquisition expenses. Potential Improvements Over the development of this idea, there were many improvements that could have been made, many of which were stifled by cost or design size criteria. The simplest way to upgrade the design would be to utilize an adhesive (i.e. command strips, Velcro strips, etc.) that would adhere the bottom of the shelf to the top of the dock. This would negate the deflection in the rigid arms and really solidify the unit to the door of the refrigerator. Unfortunately, this would remove the possibility of sliding the Egg Carriage back and forth to dynamically adjust space on demand. The most glaring detail of this design is the capacity for only 10 eggs, rather than the standard dozen. Due to the static sizes of most eggs, it was not possible to create a tray of this design that held the remaining two without exceeding the length restriction (9.9 inches) of this challenge. However, part of the design intent was to include the potential for unbridled expandability along that length if one were to have access to a 3D printer with a larger workable area. One of the unofficial challenge guidelines was to make it fit my refrigerator. However, for consumer product design, there is no such concept. That is where modularity and universality come into play. The rigid arms that hang on to the Egg Carriage are a static height that allows the Egg Carriage to be placed neatly underneath the shelf. However, with telescoping arms and a locking mechanism, one could have a dynamic length that can be adjusted for any consumer’s refrigerator.
  • 15. P a g e | 6 Another possible, but minor, improvement would be to increase the size of the magnets. Neodymium magnets are strong, but their pull-force is still proportionate to their size; a larger diameter or thickness would allow for a better factor of safety. Because neodymium magnets are graded, with the utilized N42 being of a lower end, a higher grade magnet will also yield a larger pull-force. My final suggestion for design improvements would be full incorporation onto a refrigerator door. This means that the docking system is molded with the rest of the door at the manufacturing stage for a flush, clean design; the tray would simply click onto the door itself. The elimination of the hanging arms will allow a skeptical consumer to accept the “my eggs are simply dangling there?” concept with much more relief. This static design does come with downsides in terms of mobility, but a huge boost in rigidity and aesthetic. At $39 per unit, this design is a little more on the pricy side. To allow it to be a little C. CHO, FirstBuild 11/20/2014 more economical, some compromises can be made regarding material and design. Seeing as the material is 93% of the cost, one can definitely make changes to where the filament is supplied. However, the MakerBot Replicator (5th Generation) is only designed to spool proprietary filament without modifications. When comparing with prices from third party suppliers, filament at 40-60% of the original cost will directly correlate with 40-60% reduced cost when fabricating the Egg Carriage. For a volumetrically large print such as this, it may be cost effective to make modifications for the MakerBot to accept non-proprietary filament, or print on a less restrictive machine. The other option to reduce overall cost is to cut corners on the design itself. Optimization of material usage will trade structural rigidity for price, however, that degree of optimization extends beyond the scope of this report.
  • 16. P a g e | 7 C. CHO, FirstBuild 11/20/2014 Weight Analysis Name Quantity Volume (cm3, in3) Material Weight (g, lbs) Tra y 1 242.26 (14.78) ABS P lastic 302.83 (0 .66763) Dock 1 297.93 (18.18) ABS Plastic 372.41 (0.82102) Linkage 1 2 2.045 (0.125) ABS Plastic 2.556 (0.00564) Linkage 2 2 1.643 (0.100) ABS Plastic 2.054 (0.00453) Outer Connector 1 2 0.049 (0.003) ABS Plastic 0.061 (0.00013) Outer Connector 2 2 0.043 (0.003) ABS Plastic 0.054 (0.00012) Outer Connector 3 2 0.075 (0.005) ABS Plastic 0.094 (0.00021) Outer Connector 4 2 0.107 (0.007) ABS Plastic 0.134 (0.00030) Inner Connector 1 2 0.035 (0.002) ABS Plastic 0.044 (0.00010) Inner Connector 2 2 0.032 (0.002) ABS Plastic 0.040 (0.00009) Neodymium Magnet 8 0.101 (0.006) NdFeB 0.752 (0.00166) Eggs 10 - - 1380.00 (3.04200) Total with Eggs - - - 2061.03 (4.5421) Total without Eggs - 544.32 (33.216) - 681.03 (1.5014) Table 2: Bill of Materials; refer to separate Parts List for component representation Average Weight of Extra Large Egg[4] 63 ~ 69 g (0.139 ~ 0.152 lbs) Maximum Egg Capacity 10 eggs Factor of Safety 2 Table 3: Weight Analysis of Eggs [ ] ( ) Average Volume of Neodymium Magnets 0.101 cm3 (0.006 in3) Density of Neodymium Magnets[5] 7.45 g/cm3 (0.269 lbs/in3) Number of Magnets in Tray 4 pieces Factor of Safety 2 Table 4: Weight Analysis of Magnets [ ⁄ ] ( )
  • 17. P a g e | 8 C. CHO, FirstBuild 11/20/2014 Volume of Tray 242.26 cm3 (14.78 in3) Volume of Linkages 7.38 cm3 (0.44 in3) Volume of Connectors 0.682 cm3 (0.044 in3) 3D Printed PLA Filament Density[1] 1.25 g/cm3 (0.045 lbs/in3) 3D Printed ABS Filament Density[1] 1.04 g/cm3 (0.038 lbs/in3) Factor of Safety 2 Table 5: Weight Analysis of 3D Printed Components [[ ] ⁄ ] ( ) ( ) Design Strength 2011.83 g (4.435 lbs) Magnetic Pull Force[6]: - Magnet to Magnet Contact - Grade N42 Neodymium - 0.250” Diameter - 0.125” Thickness 1043.26 g (2.30 lbs) Magnet Count 4 pieces Table 6: Pull-Force Analysis of Magnets ( ) Conclusion Based on the calculations above, the combined pull force of the Neodymium magnets (9.2 pounds) far exceeds the weight of the tray, linkages, connectors, as well as a maximum capacity of eggs combined (4.435 pounds), inclusive of the factor of safety. With these calculations, this choice of magnets allows a safety factor of 4. If a factor of safety higher than this is desired, a higher grade of Neodymium magnets may be considered, as well as an increase in the size of the magnets used. It is also possible to further maximize the factor of safety by optimizing the conservancy of material when printing the tray.
  • 18. P a g e | 9 C. CHO, FirstBuild 11/20/2014 Stress Analysis Connectors The bulk of the forces that will be applied to the egg tray itself will be the downward forces of gravity. Based on the rigidity and tighter tolerances in the axial direction of the connectors, it can be assumed that the forces axial to the connectors can be neglected. When in changing state between forward and backward positioning, the majority of the stress will lie with the connectors that hold the linkages together, and hold the linkages to the tray and dock. Due to the symmetrical nature of the connector, the stress can be modeled as unidirectional in the transverse direction. Image 7: 20 lbf of transverse load on Outer Connector 4 Image 8: 20 lbf of transverse load on Outer Connector 2
  • 19. P a g e | 10 The deformation analyses were performed on the Outer Connector 4 and Outer Connector 2 components because they were the longest and shortest in length, respectively. This characteristic, combined with the consistent diameters across all the connectors, allows us to visualize the range of maximum deformations for different lengths of connectors. Not only are the simulated deformations on the magnitude of 1/1000th of an inch, but these are also conservative estimates. In practical application, some of these connectors would be reinforced by their complementing Inner Connector components. These solid Inner Connectors would be inserted into the recess of the Outer Connectors, effectively creating a solid cylinder. The bending moment for a solid cylinder is much higher than that of a hollow cylinder, greatly increasing their ability to withstand deformation. Utilizing a 20 pound-force load was quite safe as well, considering the maximum weight of a full egg tray was calculated to be 3.721 pounds. Even if one were to accidentally bump or mishandle the egg carriage during use, the magnets and tight tolerance of the linkage/connectors would keep the cargo intact, while the strength of the connectors would not allow the rigidity of the system to collapse. Analysis of the linkages themselves was deemed unnecessary, as their presence merely represents a guide for the motions of the tray. The forces exerted on the system that maintains the tray preside mainly with the connectors’ rigidity and the pull-force of the neodymium magnets. C. CHO, FirstBuild 11/20/2014 Arms One of the design intents was to eliminate the need for an excessive footprint to store eggs. Given their fragile nature, a secure environment must be enforced. As the entire structure is hanging off of the shelf’s “fence”, the arms that secure the unit must be able to withstand the maximum weight of the egg carriage with a factor of safety. Image 9: Displacement from 20 lbf of downwards-facing load on the Tray
  • 20. P a g e | 11 C. CHO, FirstBuild 11/20/2014 Image 10: Displacement from a 20 lbf of downwards-facing load on the Tray (view from other side) Given that the weight of a full capacity Egg Carriage is projected to be 4.542 pounds, the arms must be able to withstand that force with minimal deflection. Given the positioning of the carriage, it is unlikely that any kind of accidental bumping or knocking will apply a downwards force on the carriage itself; it is more likely for the hooks themselves to absorb any such impacts. Thus, only the weight of the tray and its cargo was considered as contributing factors in this simulation. As seen in the displacement results from an applied 20 pound force (safety factor of 5), the front and back of the arms receive minimal change in position, with the blue to light blue color labels signifying a ranging displacement from 4.000 x 10-32 in to 0.200 in, respectively. The displacements near the back of the unit are larger, but an expected phenomenon due to the nature of the carriage’s shape. Potential solutions to resolve this minor issue was presented previously under Design Considerations, Potential Improvements. In the realm of permanent deformation or potential fracture, the theoretical maximum deformation can be calculated. Uniform gravitational force over the area can be summed into one resultant vector at the center of gravity. The moment is uniform along the beam in question because the distance from the force vector and then centroid of the beam is constant. Image 11: Force Vector Diagram
  • 21. P a g e | 12 Image 12: Dimensions of Cross Section and Center of Gravity (inches) Image 13: Dimension to Pivot Point (inches) C. CHO, FirstBuild 11/20/2014 Elastic Modulus of 3D Printed PLA[7] 3368 MPa (488487 psi) Applied Force 20 lbs (9071.85 g) Distance to Center of Gravity 2 in (50.80 mm) Length of Assumed Cantilever 4 in (101.60 mm) Cross-Sectional Base 0.375 in (9.53 mm) Cross-Sectional Height 0.375 in (9.53 mm) Table 7: Stress Analysis of “Cantilever” Arms ( ) ( ) ( )( ) ( ⁄ ) [ ( )( ) ] The max deflection of the hanging arm will be almost 1/10th of an inch at the point where the arm meets the main body of the dock. However, this is for an extremely conservative 20 pound force analysis. Given that these equations are linear, the max weight of the entire assembly is a little less than 5 pounds, so the practical maximum deflection at that point will be a quarter of this value, or 0.025 inches.
  • 22. P a g e | 13 From the simulated stress image below, the stress is maximum near the point previously calculated, but is limited to only 2906 psi and at no risk of fracture due to the material’s high rigidity[8]. C. CHO, FirstBuild 11/20/2014 Image 14: Stress from 20 lbf of downwards-facing load on the Tray
  • 23. P a g e | 14 C. CHO, FirstBuild 11/20/2014 References [1]http://www.toybuilderlabs.com/blogs/news/13053117-filament-volume-and-length [2]http://store.makerbot.com/pla-filament#rep-truewhite [3]http://www.kjmagnetics.com/proddetail.asp?prod=D42E [4]http://www.fsis.usda.gov/wps/portal/fsis/topics/food-safety-education/get-answers/food-safety- fact-sheets/egg-products-preparation/shell-eggs-from-farm-to-table/#17 [5]https://www.kjmagnetics.com/specs.asp [6]https://www.kjmagnetics.com/calculator.asp [7]https://www.academia.edu/6209168/Mechanical_properties_of_components_fabricated_with _open-source_3-D_printers_under_realistic_environmental_conditions [8]http://bme.ucdavis.edu/team/equipment/3d-printer-comparison/