The document summarizes the design and engineering of an Ice Crystal Replicator instrument for MMM. It describes breaking the redesign process down into simple steps over 2 months. Important calculations included thermal expansion to prevent jamming or breaking glass operating at -40°C. The instrument has 35 parts, 5 sub-assemblies and is made from materials like aluminum, Delrin, and polycarbonate. Testing was needed to ensure proper functioning. Lessons learned included attention to detail, never assuming a design is complete without testing, and buying quality materials.
1. Documentation of the MMM
Ice Crystal Replicator
Julian Claudio
University of Colorado at Boulder, Mechanical Engineering
Summer Undergraduate Program for Engineering Research (SUPER)
August 10th, 2016
2. Background
The goal of this project was to document and design
the Ice Crystal Replicator instrument that MMM has been
using since the 1990s but for which they never had CAD
models or drawings. The instrument needed to be modified to
adjust to a new film size and a larger motor for a team of
German scientists working with MMM scientist Carl Schmitt.
4. Methods
The process can be broken down into simple steps:
(2 weeks) – Design/Drawing
• Part Design
• Assembly of Parts
• Part Drawings
(4 weeks) – Review
• Design Review (Customer)
• Redline Process
(4 days) – Fabrication
(2 days) – Testing
14. Challenges
• Designing and drawing for machining, tolerances on
the engineering drawings were evaluated for
functionality and manufacturability.
15. Challenges
• Glass tubes; thermal compression was a large factor, o-ring
groove and cap diameter had to seal but not break the glass
at low temperatures.
16. Lessons Learned
• Attention to detail is key in engineering.
• Never assume you’re completely done until
testing is complete.
• Learned appropriate tolerancing and
designing for manufacturing.
• Always buy quality materials if you can help it.
17. Special Thanks
• Jim Ranson – Mentor/DFS Manager
• Karl Schwenz – Machine Shop Supervisor
• Instrument Makers
• Chris Burghart & Nick Potts – SUPER Cooridnators