Jacob collaborated in a team of four to reverse engineer and redesign a popcorn maker to improve customer satisfaction. The team first needed to research past customer reviews to focus on an area of weakness in product design that could be improved upon. After researching the reviews and finding flaws in the original product, a modification was to the popcorn maker was designed to improve the quality of the popcorn, which in turn results in improved customer satisfaction. CAD models of the device parts and modification were then created in SolidEdge and then combined together into an assembly file to display how the modification would impact the overall design of the product. The team presented a 63 page final report to faculty and peers containing the device modification and the corresponding SolidEdge models

1. D A N I E L L E G O L D I N S K Y
D I M I T R I G R A M M A T I K O P O U L O S
POPCORN MAKER
REVERSE ENGINEERING DESIGN
J A K E G R O E Z I N G E R
E U G E N E M E R E C K I
WTSN 103 Section 56 Team 2

2. OVERVIEW
• Project Information
• Product Description
• Functional Decomposition Documents
• Schematic, flowchart, and spreadsheet
• Bill of Materials
• Original Design
• Exploded & assembled views, detailed drawings
• Product Criteria
• Evaluation Methods
• Paul & Beitz and Pugh’s
• Modified Design
• Modified Decomposition Documents
• Conclusion
• References
WTSN 103 Section 56 Team 2

3. PROJECT INFORMATION
• What did we do?
• Research
• De-construct
• Model
• Document
• Brainstorm
• Why did we do it?
• Improve functionality of product
• Boost Customer Satisfaction
• Problem Statement
• Based on the current design, popcorn is being sporadically ejected
from the chute, causing difficulties for any bowl to collect all of the
popcorn
WTSN 103 Section 56 Team 2

4. PRODUCT DESCRIPTION
• Old Fashioned Popcorn Maker
• Company: Nostalgia Electrics
• Cost: $17.88 + shipping and handling
• Made in China
WTSN 103 Section 56 Team 2

5. FUNCTIONAL FLOWCHART
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Produces
popcorn
Heats
popping
chamber
Heats kernels Pops kernels
Houses
popcorn
Contains
kernels in
popping
chamber
Stores cooked
popcorn in
main housing
section
Dispenses
popcorn
Expels
cooked
popcorn out
chute
Empties out
machine for
next use

6. DECOMPOSITION SPREADSHEET
WTSN 103 Section 56 Team 2
Part Input Function Output
Screw (1) 18-8 Stainless Steel Rotational force Fastens two parts together Rotational force
Special Screw (2)
18-8 Stainless Steel
Rotational force Fastens two specific parts
together
Rotational force
Bolt (3) 18-8 Stainless Steel Mechanical force Fasten parts together Mechanical force
Kernel Measuring Cup (4)
Polypropylene
Mechanical motion Measures, scoops, and pours
kernels
Material flow
H-Bar (5) Polypropylene Mechanical Supports back of assembly Mechanical force
Nut (6) 18-8 Stainless Steel Mechanical force Holds bolt (3) in place Mechanical force
Clear Plastic Cover (7)
Polypropylene
Mechanical force Encapsulates popcorn
chamber
Material flow

7. DECOMPOSITION SPREADSHEET
WTSN 103 Section 56 Team 2
Part Input Function Output
Handle (8) Polypropylene Mechanical motion Provides mobility to
assembly
Material flow
Decorative Upper ½ of Top
(9) Polypropylene
Material flow Holds Kernel Measuring Cup
(4)
Mechanical force
Kernel Chamber (10)
Aluminum 1350
Mechanical force Contains kernels until fully
popped
Mechanical force
Metal Slanted Plate (11)
Aluminum 1350
Mechanical force Directs flow of popcorn Material flow
Decorative bottom ½ of top
(12) Polypropylene
Mechanical force Covers the top of machine Mechanical force
Kernel Chamber Holder (13)
Polypropylene
Mechanical force Holds inner components Mechanical force
Motor Casing (14)
Polypropylene
Mechanical force Encases motor (22) Mechanical force

8. DECOMPOSITION SPREADSHEET
WTSN 103 Section 56 Team 2
Part Input Function Output
Brass Chamber Bar (15)
Aluminum 1350
Mechanical force Fastens all four side of plastic
cover
Mechanical force
Fan Component (16)
Aluminum 1350
Rotational force Moves kernels in chamber
(10)
Mechanical motion
Heating Component (17)
Various
Electrical flow Pops kernels Thermal energy
Circular Metal Clamp (18)
Aluminum 1350
Mechanical force Fastens wires together Mechanical force
Red Connecting Bar (19)
Polypropylene
Mechanical force Fastens metal slanted plate
(11) to kernel chamber
holder (13)
Mechanical force
Large Heat Protector (20)
Fiberglass 320
Mechanical force Protects kernel chamber (10)
from overheating
Mechanical force
Small Heat Protector (21)
Fiberglass 320
Mechanical force Protects upper and lower ½
of top (9,12) from
overheating
Mechanical force

9. DECOMPOSITION SPREADSHEET
WTSN 103 Section 56 Team 2
Part Input Function Output
Motor BB (22) Various Electrical flow Converts electricity to
mechanical force
Mechanical motion
Wheel (23) Polypropylene Mechanical force Holds popcorn maker up Mechanical force
Hub Cap (24) Polypropylene Mechanical force Secure half axle (25) to
wheel (23)
Mechanical force
Half Axle (25) Polypropylene Mechanical force Connects wheel (23) to
kernel chamber holder (13)
Mechanical force
Kernel Catcher (26)
Aluminum 1350
Mechanical force Pushes kernels back down to
kernel chamber (10)
Mechanical motion
Popcorn Chamber Extender
(27) Aluminum 1350
Mechanical force Contains kernels that escape
kernel chamber (10)
Mechanical force
Power Cord (28)
rubber, copper
Electrical flow Provides electricity for
machine to run
Electrical energy

10. PHYSICAL SCHEMATIC
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11. PHYSICAL SCHEMATIC
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12. BILL OF MATERIALS
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13. BILL OF MATERIALS
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14. BILL OF MATERIALS
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15. BILL OF MATERIALS
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16. ASSEMBLED VIEW
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17. EXPLODED VIEW
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18. CLEAR PLASTIC COVER
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19. DETAILED DRAWING
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20. CRITERIA
Safety (.25)
• Unlikely to inflict injury
• Avoid any risk of burning
• Electrical components shielded from contact
Cost (.15)
• Affordable for the average consumer
• Minimal capital investment for modification
Time Efficiency (.20)
• Cannot slow down cooking process
• More popped in less time
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21. CRITERIA
Durability (.10)
• Lasts an extended amount of time
• Stay intact when moved
• Maintain the same work efficiency after being transported
Cleanliness (.10)
• Kernels will not be pre-ejected
• All popcorn will land in the designated container
Quality (.20)
• Majority of kernels popped
• No burnt kernels
WTSN 103 Section 56 Team 2

22. ALTERNATIVE SOLUTIONS
• Removable flap over the kernel chamber
• Deepen the kernel chamber
• Lower height of kernel catcher
• Re-shape mouth funnel
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23. PAUL AND BEITZ METHOD
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24. PUGH’S METHOD
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25. MODIFIED CLEAR PLASTIC COVER
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26. MODIFIED DETAILED DRAWING
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27. MODIFIED EXPLODED VIEW
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28. MODIFIED ASSEMBLED VIEW
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29. MODIFIED FUNCTIONAL FLOWCHART
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Produces
popcorn
Heats
popping
chamber
Heats kernels Pops kernels
Houses
popcorn
Contains
kernels in
popping
chamber
Stores cooked
popcorn in
main housing
section
Dispenses
popcorn
Expels
cooked
popcorn out
chute
Empties out
machine for
next use

30. MODIFIED DECOMPOSITION SPREADSHEET
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*new spout with narrower opening
Part Input Function Output
Screw (1) 18-8 Stainless Steel Rotational force Fastens two parts together Rotational force
Special Screw (2)
18-8 Stainless Steel
Rotational force Fastens two specific parts
together
Rotational force
Bolt (3) 18-8 Stainless Steel Mechanical force Fasten parts together Mechanical force
Kernel Measuring Cup (4)
Polypropylene
Mechanical motion Measures, scoops, and pours
kernels
Material flow
H-Bar (5) Polypropylene Mechanical Supports back of assembly Mechanical force
Nut (6) 18-8 Stainless Steel Mechanical force Holds bolt (3) in place Mechanical force
Clear Plastic Cover (7)
Polypropylene*
Mechanical force Encapsulates popcorn
chamber
Material flow

31. MODIFIED PHYSICAL SCHEMATIC
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New designed spout
Narrower opening

32. CONCLUSION
• Customer Reviews 
• Product Testing 
• Solid Edge Designs 
• Documentation & Evaluation 
• Modification 
Any Questions?
WTSN 103 Section 56 Team 2

33. REFERENCES
• DragonFly Sweetnest. N.d. Photograph. : Holiday Gift
Guide 2011: Nostalgia Electrics 'Hot Air Popcorn
Party Kit' Review/Giveaway. Web. 03 Dec. 2013.
• Vintage Series Old Fashioned Popcorn Machine, 6" X 6
1/2" X 16 1/2" N.d. Photograph. Amazon.com: :
Patio, Lawn & Garden. Web. 03 Dec. 2013.
WTSN 103 Section 56 Team 2