Speed Molding Jig

A Baccalaureate thesis submitted to the Department of Mechanical and Materials Engineering College of Engineering and Applied Science University of Cincinnati

in partial fulfillment of the requirements for the degree of

Bachelor of Science

in Mechanical Engineering Technology

Lucas Rice

April 2014

Thesis Advisor:

Professor Laura Caldwell

ACKNOWLEDGEMENTS

This project was made possible through the support and dedication of countless people who have invested in my education and life over the short span of my life. I would like to thank all of my University of Cincinnati faculty who have helped me gain my engineering degree and invested in me as a person. I want to specifically thank my Mom and Dad for their selfless efforts in educating, preparing, and supporting me in this journey of life. Always present, open to listen, willing to help and always so giving. I want to thank my precious wife Rachel for all of her tireless and ever present support in my senior year and every area of life. She is the biggest blessing in my life and keeps me running, a true example of a Proverbs 31 women. I love you Honey. Most of all, I thank my Lord and Savior Jesus Christ for giving me the mind and provision to succeed in school and for paving the way home.

TABLE OF CONTENTS

ACKNOWLEDGEMENTS ...... II TABLE OF CONTENTS ...... III LIST OF FIGURES ...... IV LIST OF TABLES ...... V ABSTRACT ...... VI INTRODUCTION & RESEARCH ...... 1

BACKGROUND ...... 1 PROBLEM ...... 1 INTERVIEWS ...... 2 RESEARCH ...... 3 CUSTOMER FEEDBACK AND OBJECTIVES ...... 6

SURVEY ANALYSIS ...... 6 OBJECTIVES ...... 8 ENGINEERING CHARACTERISTICS ...... 9 CONCEPT GENERATION AND SELECTION ...... 10

DOUBLE SUPPORT DESIGN ...... 10 SINGLE SUPPORT DESIGN ...... 11 SLOT PIVOT DESIGN ...... 12 ADJUSTABLE ANGLE DESIGN ...... 13 DESIGN SELECTION ...... 15 GEOMETRY ...... 16

SPRING ANGLE POSITION CALCULATIONS ...... 16 DESIGN DETAILS ...... 17

FABRICATION ...... 22 PART ASSEMBLY ...... 25 DRAWINGS ...... 31 PART SURFACE TREATMENT ...... 31 MATERIALS ...... 33 TESTING ...... 34

PROCEDURE ...... 34 RESULTS ...... 34 TECH EXPO ...... 38 SCHEDULE AND BUDGET ...... 39 WORKS CITED ...... 40 APPENDIX A – INTERVIEWS & RESEARCH ...... 41 APPENDIX B - SURVEY ...... 45

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APPENDIX C - QFD ...... 46 APPENDIX D - OBJECTIVES ...... 47 APPENDIX E - SCHEDULE ...... 48 APPENDIX F - BUDGET ...... 49 APPENDIX G – DETAILED DRAWINGS...... 50 APPENDIX H – BILL OF MATERIALS ...... 78

LIST OF FIGURES Figure 1 – Milescraft Crown 45 ...... 3 Figure 2 – Crown Pro ...... 3 Figure 3 – Cut-N-Crown ...... 4 Figure 4 – Bench Dog ...... 4 Figure 5 – 12” Miter Saw...... 5 Figure 6 – Double Support Design ...... 10 Figure 7 – Single Support Design ...... 11 Figure 8 – Slot Pivot Design ...... 12 Figure 9 – Adjustable Angle Design ...... 13 Figure 10 – Adjustable Spring Angle ...... 14 Figure 11 – Adjustable Spring Angle Components ...... 16 Figure 12 – Adjustable Spring Angle Setting Slots ...... 16 Figure 13 – Isometric View ...... 17 Figure 14 – Front View – Saw Guide ...... 18 Figure 15 – Top View - Angle Measurement ...... 18 Figure 16 – Left View ...... 19 Figure 17 – Rear Isometric View ...... 20 Figure 18 – Front View ...... 20 Figure 19 – Quick Release View ...... 21 Figure 20 – Isometric View – Extension ...... 21 Figure 21 – Left Side Base...... 23 Figure 22 – Hinge Bracket Machining ...... 23 Figure 23 – Completed Hinge Bracket ...... 24 Figure 24 – Completed Hinge ...... 24 Figure 25 – Front Saw Guides ...... 24 Figure 26 – Rear Saw Guide ...... 25 Figure 27 – De-burred Workpiece Table ...... 25 Figure 28 – Exploded Line View ...... 26 Figure 29 – Workpiece Table Fit Assembly ...... 27 Figure 30 – Left Side Base Fit Assembly ...... 27 Figure 31 – Completed Fit Assembly ...... 27 Figure 32 – Left Side Base Assembly...... 28 Figure 33 – Workpiece Table Assembly ...... 28

Figure 34 – Partial Left Side Assembly ...... 29 Figure 35 – Right/Left Side Assembly ...... 29 Figure 36 – Extension Assembly ...... 30 Figure 37 – Speed Molding Jig Assembly ...... 30 Figure 38 – Rubber Feet ...... 31 Figure 39 – Fully Assembled Speed Molding Jig ...... 31 Figure 40 – Painted Part Example ...... 32 Figure 41 – Precision Numbers...... 32 Figure 42 – Labelled Pinch Points ...... 32 Figure 43 – Cutting Molding for Testing ...... 34 Figure 44 – 108 Degree Test Cut ...... 34 Figure 45 – Position Testing with 2” Boundary ...... 35 Figure 46 – Cut Through Test ...... 36 Figure 47 – Saw Guide Clearance Test ...... 36 Figure 48 – Wall Contact Test ...... 36 Figure 49 – Weight Test ...... 37 Figure 50 – Completed Speed Molding Jig ...... 37 Figure 51 – Tech Expo Booth ...... 38

LIST OF TABLES Table 1 - Survey Analysis 6 Table 2 – Engineering Characteristics 9 Table 3 – Weighed Rating Method 15 Table 4 – Part Processing Matrix 22 Table 5 – Material Breakdown 33 Table 6 – Testing Results 35 Table 7 – Schedule 39 Table 8 – Budget 39

ABSTRACT

The Speed Molding Jig was developed to help both homeowners and professionals overcome the challenges of cutting and measuring crown molding in the installation process

The purpose of this report is to convey the Speed Molding Jig’s concept, design, fabrication, testing, and other pertinent information which lead to its creation and award winning performance.

The completed design stemmed from a series of four alternative designs. With the design selected, modeling and FEA was completed through the use of SolidWorks design software. The fabrication process was completed through machining, laser cutting, and assembly of all parts to build the project prototype. Two prototypes were built, one for testing and one for demonstration. The testing prototype was tested for accuracy, repeatability, and rigidity. These tests had a 100% pass rate and rendered the project complete by the approval of the faculty adviser. This level of performance caused it to receive the 1 st place award in Excellence for Best of Mechanical Engineering Technology at the 2014 University of Cincinnati Tech Expo. Even with achieving this level of success, the project was completed on time and 85% under budget. Additionally, all key objectives determined beforehand, were achieved and performed as desired.

In the end, the Speed Molding Jig project succeeded with the greatest level of excellence in fulfilling the requirements of the Senior Design course to complete the Mechanical Engineering Technology degree course of study.

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INTRODUCTION & RESEARCH

BACKGROUND

Crown molding is a simple method to add value to any home and to create greater eye appeal to even the drabbest rooms. The current method of installing crown molding is done with a saw, angle gauge, tape measure and install knowledge. With these tools and skills, the angles of corners are able to be measured and cutting locations calculated (half angles must be calculated), and the crown cut using an upside down backwards work piece positioning technique. With the crown molding cut it may be precisely installed. The new crown molding is then ready for paint or stain and the room transformation is complete.

PROBLEM

As the “Background” section testifies, crown molding installation requires special skills and tools. Homeowners and Do-It-Yourselfers often have the desire to install crown to maximize the appeal and value of their home, but lack the skills. This leaves them with limited options: either hire a professional, risk a costly mess, or go without.

Hiring a professional is a costly endeavor and creates difficulties when simply attempting to select a reputable contractor. While contractors may be costly, an even more costly or even dangerous mess can be created by an un-experienced individual.

This mess can be created by miss measuring and cutting the molding (which can run up to several dollars per linear foot), rendering several feet of molding as useless. Similarly, improper installation can leave gaps and sags, leaving all the installed molding as scrap. The dangerous mess can be generated through improperly attempting the use the upside down and backward cutting methods. This can result the loss of fingers or worse.

Finally, going without simply just does not solve the desire of the homeowner to add value to their surroundings and greatest investment: their home.

Each of these issues bring rise to the primary problem: no efficient tool or method exists to install crown molding by an inexperienced home owner. Additionally, the tricks and methods used by professionals can be time consuming and cumbersome. With no tools available to help, it even leaves the professional with the complicated method of install. Thus, without install knowledge, skills, or money, an individual is unable to meet their desire for crown molding.

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INTERVIEWS

Interviews were conducted on three distinct sections of the product audience. These three areas consisted of a homeowner with Do-It-Yourself aspirations, a professional installer, and a Do-It-Yourself homeowner. Rachel Spurlock is a homeowner with three months of home renting experience. She has a desire to be creative with her home through the use of crown molding, and a willingness to try new things. In the interview, she expressed that she didn’t feel comfortable attempting a crown molding installation without an assistive device and was unwilling to hire a professional due to cost. Throughout the discussion, Spurlock mentioned that an easy to use, simply designed, lightweight, work holding and angle measuring tool would cause her to attempt the install herself (1).

Ed Kiernan is a remodeling professional with over ten years of industry experience. He specifically specializes in interior and exterior trim installation. When the Speed Molding Jig was described to him, he showed interest in the fact that it could save him time and the labor of carrying extra tools and heavy equipment. His primary concern was that it would be able to provide the level of precision required for proper crown molding cutting and measuring. Kiernan’s comments demonstrated that he desired a durable, light weight and small tool that was adjustable to various angles of install. Throughout the interview, he emphasized the importance of accuracy. He mentioned that if it contained the accuracy required for his job, that it would be a useful tool to have in his hand (2).

Jon Heslop is an avid Do-It-Yourself homeowner. He has experience installing crown molding and understands the skills required to install quality crown molding in one’s home. In discussion of the tool, Heslop was adamant about the importance of holding the measured angle. This was in reference to maintaining the measured wall angle from the wall to the cutting surface, then to the molding. He felt that in order for this tool to be a success and useful, it must work well, and well built. As a homeowner, he mentioned that it would encourage other Do-It-Yourselfers to use the tool if it was low cost. Heslop felt that though the actual device was unique, it had a market among homeowners (3).

Complete interview notes can be referenced in Appendix A.

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RESEARCH

In the process of understanding the market and related equipment, research was performed on similar products. It was determined that no products directly resembled the Speed Molding Jig as seen in the following research explanation.

Milescraft Crown 45 Molding Cutting Jig

The Milescraft Crown 45 Molding Cutting Jig represents the majority of commercially available crown cutting assistance devices. The tool simply supports the crown molding in install position, as seen in Figure 1 (4).

Figure 1 – Milescraft Crown 45

The Crown 45 has the ability to hold the molding in three various spring positions: 38, 45, or 52 degrees depending upon the molding type. This device does not measure the wall angle or demonstrate the proper cutting angle on the molding. The simple design and light weight construction provides for a low cost product, normally selling for $30. It primarily acts as a work holding device to assist in cutting the crown in install position (4).

Crown Pro

The Crown Pro by Kreg is designed to hold the crown molding during cutting in an install position, as seen in Figure 2 (5).

Figure 2 – Crown Pro

As seen above, the Crown Pro holds the molding in the install position but is able to compensate for spring angles from 30 to 60 degrees. This jig does not measure the cut angle or guide the user to the proper cutting location. The simple and single use design creates a

3 SPEED MOLDING JIG Lucas Rice low cost tool for the market, usually selling for $30. The Crown Pro is simply a work holding jig to assist with install position cutting (5).

Cut-N-Crown

The Cut-N-Crown is designed to hold the crown molding during cutting in an install position, as seen in Figure 3 (6).

Figure 3 – Cut-N-Crown

As seen above, the Cut-N-Crown comes in three varying spring angles: 30, 45, or 52 degrees. Using three distinct tools for one task, holding the crown for cutting, creates a space consuming product at high cost. This device usually sells for $150. This jig does not measure the cut angle or guide the user to the proper cutting location. The Cut-N-Crown is simply a work holding device that holds the molding in install position for cutting (6).

Bench Dog Crown Cut Molding Cutting Jig

The Bench Dog Crown Cut Molding Cutting jig is a bench vise that enables the holding of crown molding for cutting in install position as seen in Figure 4 (7).

Figure 4 – Bench Dog

As seen above, the Bench Dog simply clamps the crown molding into install cutting position. This tool does allow for any standard spring angle of molding to be cut in install position. The design requires careful tuning of the spring angle adjustment and angle measurement. It does not lead the user to the proper cutting position. The wide adjustment range creates a

4 SPEED MOLDING JIG Lucas Rice more costly product that usually sells for $45. The Bench Dog is simply a work holding device that holds the molding in install position for cutting with a large spring angle compensation range (7).

12” Dual-Bevel Sliding Compound Miter Saw

The 12” Dual-Bevel Sliding Compound Miter Saw by Milwaukee is a miter saw that can be adjusted digitally to any angle of cut between 0 and 48 degrees. As seen below in Figure 5 (8), the rugged construction and size lead to a precise product.

Figure 5 – 12” Miter Saw

As seen above, the construction boasts an accuracy of 0.1 degrees. The fencing enables and type of crown molding to be cut in the upside down backwards positioning style. While the miter saw performs an extremely accurate cut, it does not measure the required wall angle. The precision and advanced motor technology creates a market price of $649. Additionally, the heavy construction weighs in at 65 pounds, making it difficult to move and handle. The miter saw excels in cutting accurately, but fails to help hold the molding in install position and to measure the wall angle (8).

Additional research material can be referenced in Appendix A.

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CUSTOMER FEEDBACK AND OBJECTIVES

SURVEY ANALYSIS

A survey consisting of a features list was presented to various representatives of the target audience. The 12 individuals surveyed contained homeowners, Do-It-Yourselfers, interested individuals, and tool enthusiasts. Each surveyed feature requested a response of how important the item was to the individuals, 1 being unsatisfied and 5 being greatly satisfied. Results for the survey can be seen below in Table 1, coupled with the designer multiplier and planned satisfaction.

Table 1 - Survey Analysis

CustomerImportance Multiplier Designer’s Satisfaction Current Planned Satisfaction Ratio Improvement Modified Importance Relative Weight Relative Weight % Durability 4.8 1.1 4.2 5 1.2 5.7 0.13 15% Ease of Operation 4.4 1.1 3.7 4 1.1 5.3 0.13 12% Operation by One Person 4.4 1 4.2 5 1.2 5.3 0.13 12% Sufficient Precision 4.7 1 3.5 4 1.1 5.3 0.13 12% Light Weight 2.9 1.1 3.5 5 1.4 4.6 0.11 11% Ease of Maintenance 3.8 1 3.3 4 1.2 4.6 0.11 11% Affordability 3.3 1 3.2 4 1.3 4.2 0.10 10% Safety 4.3 1 4.2 4 1.0 4.1 0.10 10% Small in Size 2.8 1 3.5 4 1.1 3.2 0.08 8% Flexibility 0 0 0 0 0.0 0.0 0.00 0%

* Note: Due to rounding, percentages may equal greater than 100%

As the survey results above denote, the customers are most concerned about the Durability, as it received 4.8 of 5. Tools and their accuracy are directly correlated to their durability by consumers. A tool with high durability is normally more accurate. As seen in the results, Accuracy is the customer’s second most important feature with 4.7. With this direct correlation supported by the survey, the designer’s multiplier of 1.1 was applied to the feature of durability. Attention from the designer on durability helps to achieve the precision and durability desired, while also increasing the customer’s product trust.

Naturally as the survey states, any user of the tool desires accuracy and durability to complete the job at hand. Durability adds to the life span of the tool making it a useful tool for numerous projects. Next to the durability and precision, ease of operation is of great

6 SPEED MOLDING JIG Lucas Rice importance, for a difficult to use product is worthless to the consumer.

The feature of Ease of Operation was ranked by consumers as a 4.4, but was increased in importance by a designer’s factor of 1.1. The multiplier was given because all the competing equipment and expressed opinions of the interviewees all require easy operation. Additionally, without ease of operation, the product violates the expressed problem statement of creating a tool for an individual to easily install crown molding.

Ease of operation allows the user to effectively use the features designed into the equipment and ensures a quality experience. In order to achieve the highest level of consumer satisfaction the weight was considered as high importance from the designer’s perspective.

While the Light Weight feature is second to the least important feature (receiving a 2.9), it received a 1.1 designer’s multiplier. This multiplier was selected because a light weight tool would allow for easy operation and keep the durability facture in check, steering away from using heavy materials. Selecting an increased factor also forces the design to rely on the product structure and materials rather than bulk.

Planned satisfaction represents the satisfaction of the consumer after using the device. All features (except safety) show an increase in consumer satisfaction. This increase is driven by the aspect that the market is devoid of similar devices and based upon the logic that selling a quality product requires improvement over the expectations. The features of Light Weight and Durability are both listed as planned satisfaction of 5. This rating states that after consumer use, there are no areas of improvement. These ratings were given in correspondence to the consumers rating and the designer’s multiplier. In order to achieve a light weight and durable product, the current satisfaction must be exceeded for best performance. The planned satisfaction of safety remained stationary due in part by the subjective manner to which it is determined and the relative low ranking given by consumers. Flexibility was not given a planned satisfaction because the weight was 0%.

Additional survey results and actual counts can be seen in Appendix B with added QFD details in Appendix C.

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OBJECTIVES

The product objectives are a list of features which are directly related to the customer survey, and considered throughout the design process. The following list of features is ranked in accordance with consumer importance and provides targets for measureable satisfaction. Additional details can be viewed in Appendix D.

1. Durability (15%) a. Built from aluminum with all bolts torqued to spec or single piece machined b. All machined components greater then 1/8 inch thick c. Wear surfaces covered in appropriate wear material 2. Ease of Operation (12%) a. One step angle locking b. Labels and numbers with minimum 16pt font c. Guides remain rigid (flexure under 3/16 inch) during cutting 3. Operation by One Person (12%) a. Jig can be used for measuring wall angle or cutting on a bench by one person b. Grip points for carrying and holding within ergo specifications c. Eye holes in corners for bench mounting 4. Sufficient Precision (12%) a. Molding “A” surface gap less then 1/16 inch on cut molding when installed b. Prototype built from aluminum c. Set-screw for locking and angle holding d. Saw guide for holding saw in cutting position e. Measures half (0.5) degree increments with one (1) degree numbers 5. Ease of Maintenance (11%) a. All components removable with single tool b. Cutting location open for dust removal 6. Light Weight (11%) a. Product (prototype) is less then seven (7) pounds 7. Safety (10%) a. Set-screws and hand components all ergonomically compliant b. Pinch points all labeled c. Rubber feet to limit movement during normal operation to under two (2) inches d. Guides hold saw from slipping toward off-hand (work piece holding hand) e. Radius or filleted edges 8. Affordable (10%) a. Meets or surpasses cost value as set by survey for manufacturing 9. Small in Size (8%) a. Able to fit in average two (2) cubic foot tool box/bag b. Can to be carried with one (1) hand 10. Flexibility (00%) a. Measures wall angles between 0 and 270 degrees (minimum) b. Can measures outside and inside corners c. Able to hold one (1) inch to six (6) inch wide molding

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ENGINEERING CHARACTERISTICS

The engineering characteristics are methods for satisfying all the consumer features in design. The list of engineering characteristics ordered by relative importance can be seen below in Table 2.

Table 2 – Engineering Characteristics

Relative Engineering Characteristic Importance Material Selection 12% Surface Friction 9% High Rigidity (under 3/16” flexure) 8% Few Components 7% Handles 7% Saw Guides 7% Bench Mounting 6% Components Bolted or Machined 6% Finger Clearance 6% One Step Locking 6% Greater Then 1/8” Thickness 5% Open Cutting Location 4% Single Bolt Size 4% Measure 0 to 270 Degrees 3% Measure 0.5 Degree Increment 3% Pinch Points Labeled 3% Smooth Edges 3% Hold One (1) to Six (6) Inch Molding 3% Angle Labels 1%

The characteristic rankings allow for more efficient decisions during the design process. All choices were made in an effort to favor the characteristics with greatest relative importance in order to meet the largest number of features. As seen above, the Material Selection is most important and will thus be focused on during design. Conversely, Angle Labels are least important and were eliminated in the design process in favor of more important characteristics. Each of these characteristics has a strong impact on the features and the method of which they are achieved.

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CONCEPT GENERATION AND SELECTION

DOUBLE SUPPORT DESIGN

The first design concept generated, as shown in Figure 6, is referred to as the Double Support Design . The Double Support Design allows the user to hold the jig up into the corner, measure and set the wall angle to the jig. The angle setting is performed through the twisting of two thumb set screws by the operator. With the angle set on the jig from the wall, the molding can be cut. This design supports the crown molding on both the left and right side of the cutting location. With the double supporting method, the mating cut for the corner is able to be cut without any adjustments to the support structure, only a switch in the angle direction. The angle direction specifies the location of cut through two sets of saw guides which hold the hand saw at the correct angle of cut. The design supports up to a six inch width molding. The support of the molding is simple and supports the primary size of spring angle molding, 45 degrees. Set-up of the jig is simple in that all features remain connected and there is no assembly required for use.

Left Side Saw Guides Right Side

Pivot Point Thumb Screws

Figure 6 – Double Support Design

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SINGLE SUPPORT DESIGN

The second design concept generated, as shown in Figure 7, is referred to as the Single Support Design . The Single Support Design allows the user to hold the jig up into the corner, measure and set the wall angle to the jig. The angle setting is performed through the twisting of one thumb set screw by the operator. With the angle set on the jig from the wall, the molding can be cut. This design supports the crown molding on the left side of the cutting location. With the single supporting method, the mating cut for the corner is cut by flipping the molding over in the opposite direction. This reversing of the work piece enables cutting without any adjustments made to the support structure or saw guide direction. The angle direction specifies the location of cut through two sets of saw guides which hold the hand saw at the correct angle of cut. The position of cutting is set by the user after calculating the half angle of the measured wall angle. The design supports up to a six inch width molding. The support of the molding is simple and supports the primary size of spring angle molding, 45 degrees. Set-up of the jig is simple in that all features remain connected and there is no assembly required for use.

Workpiece Table

Thumb Screw Saw Guides

Pivot Point

Figure 7 – Single Support Design

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SLOT PIVOT DESIGN

The third design concept generated, as shown in Figure 8, is referred to as the Slot Pivot Design . The Slot Pivot Design allows the user to hold the jig up into the corner, measure and set the wall angle to the jig. The angle setting is performed through the twisting of one thumb set screw by the operator. With the angle set on the jig from the wall, the molding can be cut. This design supports the crown molding on both the left and right side of the cutting location. With the double supporting method, the mating cut for the corner is able to be cut without any adjustments to the support structure, only a switch in the angle direction. The angle direction specifies the location of cut through two sets of saw guides which hold the hand saw at the correct angle of cut. The design supports up to a six inch width molding. The support of the molding is simple and supports the primary size of spring angle molding, 45 degrees. Set-up of the jig is simple in that all features remain connected and there is no assembly required for use.

Pivot Slot Left Side Right Side

Saw Guides

Thumb Screws

Pivot Point

Figure 8 – Slot Pivot Design

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ADJUSTABLE ANGLE DESIGN

The fourth design concept generated, as shown in Figure 9, is referred to as the Adjustable Angle Design . The Adjustable Angle Design allows the user to hold the jig up into the corner, measure and set the wall angle to the jig. The angle setting is performed through the twisting of one thumb set screw by the operator. With the angle set on the jig from the wall, the molding can be cut. This design supports the crown molding on the left side of the cutting location. With this single supporting method, the mating cut for the corner is cut by flipping the molding over in the opposite direction. This reversing of the work piece enables cutting without any adjustments made to the support structure or saw guides direction. The angle direction specifies the location of cut through two sets of saw guides which hold the hand saw at the correct angle of cut. This angle is set by the user by reading the half angle dimensions from reference marks on the pivoting saw guides, originally set by the wall angle. This design supports up to a six inch width molding. The support of the molding is simple and supports the three primary sizes of spring angle molding, 32, 45, and 53 degrees. The Adjustable Spring Angle component, as seen in Figure 10, uses a primary support method and three series of positions to create the various spring angles. Set-up of the jig is simple in that all features remain connected and there is no assembly required for use. The user simply has to set the desired spring angle prior to cutting.

Workpiece Table Angle Finder

Saw Guides

Thumb Screws

Pivot Point

Figure 9 – Adjustable Angle Design

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Angle Settings

Angle Gauge

Figure 10 – Adjustable Spring Angle

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DESIGN SELECTION

The four design concepts generated all met the Design Objectives, as seen in the Objectives section of the report. With these four perspective designs, a Weighted Rating Method, as seen in Table 3, was employed to determine which design would continue in the design process. The judgment criteria of each model, as well as the importance rating, were based upon the Objectives (as outlined in Appendix D) information. With the weights determined, each design was scored with a rating between zero and four (five point scale) based upon the criteria from the Objectives . Based upon the Weighted Rating Method results, it was determined that the Adjustable Angle Design would be the best design based upon the design receiving the highest score. The selection of the Adjustable Angle design was primarily caused by the criteria of Ease of Operation, Operation by One Person, and Sufficient Precision (bolded for illustration). In these criteria, the Adjustable Angle design scored a rating of four, whereas the other designs did not score as high. Thus, these criteria attributed too much of the selection of the design.

Table 3 – Weighed Rating Method

Co ncept Alternatives Double Support Single Support Slot Pivot Adjustable Angle Importance Weighted Weighted Weighted Weighted Criteria Rating Rating Rating Rating Weight Rating Rating Rating Rating Durability 15% 3 0.45 4 0.6 2 0.3 3 0.45 Ease of Operation 12% 1 0.12 3 0.36 2 0.24 4 0.48 Operation by One 12% 3 0.36 4 0.48 3 0.36 4 0.48 Person Sufficient Precision 12% 2 0.24 3 0.36 3 0.36 4 0.48 Ease of Maintenance 11% 3 0.33 4 0.44 2 0.22 4 0.44 Light Weight 11% 4 0.44 4 0.44 4 0.44 4 0.44 Safety 10% 3 0.3 4 0.4 3 0.3 4 0.4 Affordable 10% 3 0.3 4 0.4 3 0.3 4 0.4 Small in Size 8% 3 0.24 4 0.32 3 0.24 4 0.32 Flexible 0% 4 0 3 0 4 0 3 0 100% NA 2.78 NA 3.8 NA 2.76 NA 3.89

Rating Rating Unsatisfactory 0 Tolerable 1 Adequate 2 Good 3 Very Good 4

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GEOMETRY

SPRING ANGLE POSITION CALCULATIONS

The Adjustable Angle Design requires the vertical and horizontal components of the molding to be determined at the standard angles of 32, 45, 53 degrees. These calculated dimensions allow the construction of the proper adjustable part sizes and locations, as seen in Figure 10. The horizontal distance ( X) and vertical distance ( Y) were calculated based upon the largest molding size of six inches, as seen in Figure 11, and determined in the following calculations for theta equaling 32 degrees (all calculations repeated for 45 and 53 degrees also). With the X and Y components determined, the design was able to be modeled.

Figure 11 – Adjustable Spring Angle Components

From the determined geometry, the actual adjustment slots were added to the model for use in the product, as seen below.

Spring Angle Slots

Figure 12 – Adjustable Spring Angle Setting Slots

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DESIGN DETAILS

The components of the assembly are designed with tight tolerance of +/- 0.001 inches in order to ensure an angle tolerance of +/- 0.06 degrees (also applying to the half angle) when cutting molding. All bolt diameters and threads are standardized to enable simplistic assembly and disassembly with only one tool. Fabricated parts are painted for consumer eye appeal and protection from rusting. The screws are made from black oxide coated steel to provide a clean, professional appearance and to eliminate rusting. The thumb screws are made of stainless steel to prevent rusting and to ensure ease of griping for an extended period of time. All moving pieces (i.e. thumb screws) support clearance specifications for human standards and ergonomics.

6”x9” Workpiece Table allows for easy positioning of material for cutting

Fabricated parts are painted for consumer eye appeal and rust resistance

Thumb screws are stainless steel to prevent rusting and risk of injury

Figure 13 – Isometric View

Besides maintaining a pleasing appearance, the product is simple to operate and provides the user with which leave less than 1/16” “A” surface gap, when installed, every time through fine threads (1/4”-20) and precise design (+/- 0.003” tolerance). The saw guides are self- aligning and allow the user to place their hand saw between the guides with little challenge while maintaining an accurate cutting position. The slots in the saw guides allow the user to have full depth cutting on the molding in one cutting motion and are wide enough to support most standard saws.

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Saw Guide alignment matches with zero reveal between guides to allow for smooth saw motion while

Wall thickness and material reduces lateral deflection to under 1/16 inch

Saw slot allows for single pass full depth cutting of molding and standard saw sizes Figure 14 – Front View – Saw Guide

The wall angle is easily set by user through positioning the jig into the corner of question and setting the angle with a thumb screw. A single pivot point allows the user to operate the angle measurement section with only one hand, leaving the other hand free to support the jig’s weight. All points of wall contact are rounded to reduce risk of wall damage while providing maximum angle reading accuracy. A smooth arc of the Right Side Base allows for easy movement of the Saw Guide (through the use of nylon guide pins) and a visible location for half angle markings.

3/8” Bolt holes allow for bench mounting Fluid arc for ease of angle adjustment, part movement and half angle markings Rounded touch point against wall to reduce risk of wall damage

Single pivot point for easy one handed operation Wall touch point

Figure 15 – Top View - Angle Measurement

All assembly screws are counter sunk to allow for smooth operation of the moving

18 SPEED MOLDING JIG Lucas Rice components and to provide a clean appearance to the user. Key surfaces are profiled to create clearance which prevents saw dust for hampering movement. All corners are rounded to prevent injury and to add visually smooth lines and shapes. Engineered component locations, primarily referring to the Saw Guides, prevent interference with work piece during operation. For operation, the jig is held into the corner with all the touch points contacting the wall. At which point, the pivot set screw is tightened. The jig is then placed on the table and the saw guides are set to the half angle of the measured angle. With the settings in place, the Workpiece Table is set to the desired spring angle using the Angle Gauge. After that, the molding is able to be cut and the set half angle for the right or left side.

Plane of Workpiece Table is unobstructed by saw guide positioning

Rounded edges to prevent injury and increase eye appeal

Profiled surfaces allow for smooth operation with debris

Counter sunk hardware for clean appearance and smooth operation Figure 16 – Left View

In order to allow the jig to support multiple spring angles, a series of slots are engineered into the Left Side Base and the Workpiece Table. These pairs of slots correspond to a spring angle and hold the Angle Gauge in place. Each pair is labeled with the spring angle. The slots in the Angle Gauge allow for easy user handling and reduce weight. The Workpiece Table pivot point allow for simplistic adjustability.

19 SPEED MOLDING JIG Lucas Rice

Slots allow for the key spring angles to be set on the jig

The Angle Gauge is used to set the angle and contains openings for easy handling

The Workpiece Table pivot point is based upon two ¼”-20 screws and allows simple range of motion (0-80 ̊ ) Weight reduction slots are created where material is not

required, with each corner

rounded to eliminate increased

stress points

Figure 17 – Rear Isometric View

The overall base of the jig rides on a single plane as to create a secure base for cutting and mounting. Slots for moving parts are included to enable all moving parts to slide above the base plate.

Slots for movable parts allow for movement to occur above base plates

Single base plane creates a stable foundation and easy bench mounting

Figure 18 – Front View

The opposite angle of the molding joint is cut using the Extension to prevent the molding from being turned upside down and backward. The Extension is connected to the Left Side Base through a geometric based quick connect. This connection eliminates any moving parts while ensuring a consistent and accurate connection. The tolerances of the quick connect is tight (+/- 0.001 in) to ensure an accurate connection every time.

20 SPEED MOLDING JIG Lucas Rice

Geometric based quick connect allows for an accurate connection and simple usage

The Extension can be connected to a bench top with 3/8” bolts for solid cutting and easy positioning

Figure 19 – Quick Release View

The Extension side of the jig is based on similar principle to that of the right side: single pivot point, half angle markings, self-aligning Saw Guides, and single thumb screw angle locking.

Simple-aligning saw guide to facilitate easy operation

Fluid arc for angle adjustment and half angle markings

Tab to facilitate half angle setting on radius edge

Single pivot point with thumb screw angle locking

Figure 20 – Isometric View – Extension

Careful consideration was taken during the design phase as to select standard material thicknesses that would be supported by standard fastener sizes. This enables standard sized fasteners to be purchased reducing cost and manufacturing time.

Each component is carefully engineered to allow for ease of mass production. The components are all able to be connected via simple fasteners. With the addition of di-drawl, the majority of parts could be injection molded to decrease production time and cost for large scale manufacturing. The primary base components are shaped in a manner which maximize

21 SPEED MOLDING JIG Lucas Rice the efficiency of laser cutting (rounded inside and outside corners) for speed during production.

FABRICATION

The fabrication of all components was completed through machining, laser cutting, and tapping. Each component was produced using the techniques as outlined in the following table.

Table 4 – Part Processing Matrix Laser Part Name Part # Machining Tapping Cutting Left Side Base SD102 X X Hinge Bracket SD103 X X Workpiece Table SD104 X X Hinge SD105 X X Angle Gauge SD106 X Extension SD107 X X Extension Angle Slide SD108 X X Right Side Base SD201 X Saw Guide - Rear SD202 X X X Saw Guide Lock SD203 X X Saw Guide - Front SD204 X X X

As the above table denotes, the majority of all parts were laser cut (except the Hinge Bracket and Hinge) in order to increase the speed of manufacturing, decrease in cost and to enable the use of standard materials. Additionally, since all the parts are built in di-drawl, the laser cut parts can easily be replaced with a molding process. The below figures illustrate some of the laser cut and tapped parts.

22 SPEED MOLDING JIG Lucas Rice

Tapped Holes

Figure 21 – Left Side Base

All parts which were laser cut and tapped were tapped using a ¼”-20 right-hand-thread hand tap. These holes were through tapped using a drill press to ensure a straight tap.

The machined parts as outlined in the Table 4 were created using an end mill and bench sander. The below image displays the part of the machining required for the production of the Hinge Bracket.

Figure 22 – Hinge Bracket Machining

Through multiple steps of machining, removing approximately 0.0750” per pass. Additional steps were performed using a Bridgeport to drill counter through and countersunk holes. The following images are the completed machined parts.

23 SPEED MOLDING JIG Lucas Rice

Figure 23 – Completed Hinge Bracket

Figure 24 – Completed Hinge

The only parts which were laser cut, machined, and tapped were the Front and Rear Saw Guides as depicted in the following images.

3/8” Drilled Holes

Figure 25 – Front Saw Guides

24 SPEED MOLDING JIG Lucas Rice

0.2660 Drilled Holes ¼”-20 Tapped Holes

Figure 26 – Rear Saw Guide

The 0.3750” and 0.2660” through holes for the Saw Guides were created using a Bridgeport. Each hole was center drilled prior to using the specified diameter drill bit. The ¼”-20 tapped holes were first center drilled on a Bridgeport, the drilled 0.500” deep with a 0.2010” diameter drill bit to allow for greater than 75% thread engagement. They were hand tapped until the tap bottomed in the hole, using a ¼”-20 right-hand-thread tap.

All edges of the parts after fabrication were sanded using a belt sander, sand paper or a Dyno-file in order to remove burrs and sharp edges for safety purposes. The finished edges are depicted in the following image.

Sanded Edges

Figure 27 – De-burred Workpiece Table

With all the parts fabricated, the assembly stage of the process could begin.

PART ASSEMBLY

Assembly of parts is simple as most parts are only able to fit in one location and all can be fastened with a single hex wrench or fingers. The entire assembly is assembled through only 12 ¼”-20 threaded fasteners. The exploded view of the assembly is shown below.

25 SPEED MOLDING JIG Lucas Rice

Figure 28 – Exploded Line View

The assembly of the Speed Molding Jig was completed in two steps: test fit and final assembly. The test fit assembly was performed as to ensure all parts fit properly and functioned as desired. As the following figures demonstrate, the parts were assembled in sections to test fit.

26 SPEED MOLDING JIG Lucas Rice

Figure 29 – Workpiece Table Fit Assembly

Figure 30 – Left Side Base Fit Assembly

Figure 31 – Completed Fit Assembly

With the fit assemblies completed and all parts working as designed, the parts were painted as outlined in the Part Surface Treatment section of the report. Upon completion of the painting, the final jig assembly was performed using a single tool for the 12 ¼”-20 bolts. As displayed in the following images, the assembly was performed in a step by step process.

27 SPEED MOLDING JIG Lucas Rice

Left Side Base

¼”-20 Bolts

Hinge Bracket

Figure 32 – Left Side Base Assembly

Workpiece Table

¼”-20 Bolt

Hinge

Figure 33 – Workpiece Table Assembly

With the Left Side Base and Workpiece Table Assemblies completed, they were joined together using ¼”-20 bolts, as the hinge pins, to create the Partial Left Side Assembly.

28 SPEED MOLDING JIG Lucas Rice

Workpiece Table Assembly

Left Side Base Assembly

Figure 34 – Partial Left Side Assembly

With the Partial Right Side Assembly complete, the additional components, Saw Guides, Thumb Screws, Right Side Base, and Angle Gauge, were added to complete the Right/Left Side Assembly.

Angle Saw Guides Gauge Right Side Base

¼”-20 Thumb Screws

Figure 35 – Right/Left Side Assembly

With the Left/Right Assembly completed, the Extension Assembly was built using the same methods.

29 SPEED MOLDING JIG Lucas Rice

Saw Guides Angle Slide ¼”-20 Thumb Screws Extension

Figure 36 – Extension Assembly

After completion of the Extension Assembly, the Right/Left Side and Extension Assembly were joint using the geometrical interlock to form the completed Speed Molding Jig Assembly as observed in the following image.

Figure 37 – Speed Molding Jig Assembly

The entire assembled jig weighs 8.08 pounds with the handled side only weighing 5.68 pounds. This light weight design allows for numerous hours of use and easy transport without fatigue to the user or risk of injury.

In order to assure the jig remains stationary during cutting (when bolts for bench mounting are not used) and to protect the surface finish on which the jig sits, rubber feet were added to the bottom of the jig.

30 SPEED MOLDING JIG Lucas Rice

Rubber Feet

Figure 38 – Rubber Feet

With the addition of the rubber feet and Part Surface Treatments , the jig was fully assembled to produce the Speed Molding Jig.

Figure 39 – Fully Assembled Speed Molding Jig

DRAWINGS

The detailed part and assembly drawings provide complete product specifications, which include part geometry and tolerance and material and process specification. Refer to Appendix G for details.

PART SURFACE TREATMENT

All laser cut parts are wet tumbled and sanded to remove rough edges and painted to eliminate the risk of rusting and increase visual appearance. Machined parts are sanded to eliminate rough edges and painted to eliminate the risk of rusting and to increase visual appearance. Thumb screws remain stock finish since they are made from stainless steel. Screws are black oxide coated steel to eliminate rusting and providing a premium surface appearance. The following images demonstrate the parts painted to prevent rust and increase visual appeal.

31 SPEED MOLDING JIG Lucas Rice

Figure 40 – Painted Part Example

Precision numbers were painted onto the finish and sealed with acrylic for durability. These numbers were used for adjustment and setting of the measured angles.

Figure 41 – Precision Numbers

In addition to detailed number, all pinch points were labeled with vinyl marking tape and lettering, as seen below, for safety.

Figure 42 – Labelled Pinch Points

32 SPEED MOLDING JIG Lucas Rice

MATERIALS

All laser cut components (except the Saw Guides) were designed for 5052-H32 Aluminum. This material was selected because of its ease of laser cutting and weight to strength ratio. The Saw Guides were laser cut from 1018 Pickled and Oiled Carbon Steel. This material was selected as to reduce bending and deflection during the process of cutting the molding as to meet the Objectives requirement of deflection. The Hinges were machined from 1018 Steel. 1018 Steel was selected because of the small part size and need for extra rigidity, which could not be met by aluminum. The Hinge Bracket was machined from 6061-T6 Aluminum. 6061-T6 Aluminum was chosen because of its weight to strength ratio coupled with its machinability properties (approx. 360% (9)). Table 5 outlines the materials used in the product as related to the specific parts.

Table 5 – Material Breakdown

Material Component Part No. 1018 Steel Hinge SD105 Saw Guide – Rear SD202 Saw Guide Lock SD203 Saw Guide – Front SD204 5052-H32 Al Left Side Base SD102 Workpiece Table SD104 Angle Gauge SD106 Extension SD107 Extension Angle Slide SD108 Right Side Base SD201 6061-T6 Al Hinge Bracket SD103

33 SPEED MOLDING JIG Lucas Rice

TESTING

PROCEDURE

Testing of the product was conducted through cutting 15 molding joints, basically 30 individual cuts. Each of these joints was measured to ensure no gaps exceeded a 1/16 inch. The accuracy of the angle measuring was confirmed through measuring the wall through another means and comparing to the jigs measurement reading. All standard operations were repeated for the various spring angles and at numerous degrees of cut. Each factor of the objectives was tested and the results compared to that of the requirements.

RESULTS

As outlined in the testing Procedure , 15 molding joints were cut and the “A” surface gap measured and recorded. For the purpose of repeatability and increased sample size, each angle was cut four individual times. Between each cut, the jig was set to the angle to ensure that the cuts were independent of each other. Below depicts the cutting process during testing.

Figure 43 – Cutting Molding for Testing

In order to measure and cut various angles, testing jigs were built from wood to mimic a wall corner. These jigs were built at 90, 108, and 120 degrees. From these jigs, the Speed Molding Jig was used measure the angle and cut the molding. The cut pieces of molding were then placed against the jig to determine the “A” surface gap, as seen below.

Figure 44 – 108 Degree Test Cut

From cutting and measuring these and other cut angles, the results were tabulated as seen in the below table.

34 SPEED MOLDING JIG Lucas Rice

Table 6 – Testing Results Joint Half "A" Surface Gap (in) Angle Angle Judgment (deg) (deg) 1 2 3 4

180 90 0 0 1/16 - OK 120 60 0 0 1/32 1/32 OK 108 54 0 1/32 1/32 1/32 OK 90 45 0 0 1/32 1/16 OK

From these results, it can be seen that all of the “A” surface gaps were equal to or less than the specified 1/16” gap.

For testing the positioning of the jig in use, when not bolted to the work bench, a cut was made while only holding the jig by hand and allowing the friction of the rubber feet to hold it in place. As the image below illustrates, the jig moved less than 2” which was the specified direction.

Figure 45 – Position Testing with 2” Boundary

The jig was tested for work piece clearance and for cut through with the saw. As the following images demonstrate, the molding has sufficient clearance between the saw guides and the saw is able to cut completely through the work piece.

35 SPEED MOLDING JIG Lucas Rice

Figure 46 – Cut Through Test

Figure 47 – Saw Guide Clearance Test

For testing of the touch locations against the wall, the jig was placed in a corner and adjusted to the angle. As illustrated from the below figure, the jig fit to the corner with all touch points contacting the wall.

Figure 48 – Wall Contact Test

To ensure the weight of the handled side of the jig (5.68 lbs) is easy to handle, a 90 th percentile female held the jig in one hand to demonstrate that it was simple to hold.

36 SPEED MOLDING JIG Lucas Rice

Figure 49 – Weight Test

With the completion of the testing and the results considered, the Speed Molding Jig was deemed complete.

Figure 50 – Completed Speed Molding Jig

37 SPEED MOLDING JIG Lucas Rice

TECH EXPO

With the project completed and the final Speed Molding Jig built, the project was presented at the 2014 University of Cincinnati College of Engineering and Applied Science Tech Expo. As depicted below, the project was displayed with details about the background, fabrication, and testing.

Figure 51 – Tech Expo Booth

The Speed Molding Jig was awarded 1 st in Excellence for the Best of Mechanical Engineering Technology. This project was select from among 35 other projects by a panel of non-UC professors and industry experts.

38 SPEED MOLDING JIG Lucas Rice

SCHEDULE AND BUDGET

The project schedule started on September 29, 2013 with content review and objective approval. The project will be completed on April 23, 2014 with the submission of the final report to the University of Cincinnati library. The project schedule spans 30 weeks from start to finish. A list of key milestone dates can be seen following table.

Table 7 – Schedule

Milestone Date 3D Modeling 10/13/13 – 12/6/13 Material Order 12/6/13 Shop Drawings 12/16/13 – 1/3/14 Fabrication 1/20/14 – 3/8/14 Testing 3/10/14 – 3/14/14 Project Presentation 4/6/14

The project budget is a rough estimate of material and labor costs based upon sketches and average material rates. Budgetary numbers reflect the presence of material removal processes as to allow for any selection of design. The addition of Misc. Service/Parts is to account for fluctuations in material and labor costs and to account for unforeseen parts. The Actual Amount section is the cost of building two units (one for display and the other for testing).

Table 8 – Budget

Materials, Components or Labor Forecasted Amount Actual Amount Raw Material $300 $28.20 Hardware $30 $65.25 Machining $200 $0.00 Misc. Service/Parts $100 $7.16 Total $650 $100.61

39 SPEED MOLDING JIG Lucas Rice

WORKS CITED 1. Spurlock, Rachel. [interv.] Lucas Rice. Cincinnati, OH, 09 03, 2013. Phone Interview. 2. Kiernan, Ed. [interv.] Lucas Rice. (513) 502-6642, 09 03, 2013. Phone Interview. 3. Heslop, Jon. [interv.] Lucas Rice. Wilmington, OH, 09 03, 2013. Phone Interview. 4. Northern Tool + Equipment. Milescraft Crown 45 Molding Cutting Jig . [Online] 2009. [Cited: 08 30, 2013.] http://www.northerntool.com/shop/tools/product_200418413_200418413?cm_mmc=Google- pla-_-Power%20Tools-_-Power%20Tool%20Accessories-_- 331404&ci_src=17588969&ci_sku=331404&gclid=CI2G7ZOlpbkCFSVgMgodJEcALg. 5. Kreg Tool. Crown Pro. [Online] 2013. [Cited: 08 30, 2013.] http://www.kregtool.com/CrownPro-Prodview.html. 6. Cut-N-Crown Inc. All Products. [Online] 2007. [Cited: 08 30, 2013.] http://www.cutncrown.com/all_products.php. 7. Bench Dog Tools Inc. Crown Cut. [Online] 2012. [Cited: 08 30, 2013.] http://www.benchdog.com/crowncut.cfm. 8. Milluakee Electric Tool Corporation. 12" Dual-Bevel Compound Miter Saw. [Online] 2013. [Cited: 09 04, 2013.] http://www.milwaukeetool.com/power-tools/corded/6950-20. 9. Engineering ToolBox. Metals Machinablity. The Engineering ToolBox. [Online] [Cited: 2 3, 2014.] www.engineeringtoolbox.com/machinability-metals-d_1450.html.

APPENDIX A – INTERVIEWS & RESEARCH

Interview with new homeowner: Rachel Spurlock. 6945 Murray Ave. Cincinnati, OH 45227 09/03/13 She has three months of home rental experience. Creative, has desire to add value to her home, hands on, crafty, and passionate for trying new things. She feels that it would save a lot of time in math and measurement of the angles/geometry. It would be wonderful time and money saving device from not hiring others. She would like add molding but doesn’t want to hire someone, but would be willing to give it a try if she had a tool to measure and cut the angles. She expressed the following features and components: Clear/simple directions on product’s packaging. Simple and easy to use, light weight, easy to clean (lack of space to collect sawdust), strong grip for holding wood, simple design (little complexity), and clearly labeled components and steps. She mentioned pink as a good color and clarified to mean she would want it aesthetically pleasing. She has never seen or found a similar device. She was excited about the concept of my project and the ability that it would give her or her friends to install molding in their homes independently while saving them time and money.

Interview with Handyman and Remodeler: Ed Kiernan. 6543 Cedar Ridge Dr. Loveland, OH 45140 09/03/13 He has been a remodeling professional for 10+ years. He specializes in interior and exterior trim work. Emphasized that product should produce precise cuts for exact corner matching and good repeatability. Recommended adjustable markers for indicating last angle measured. Clearly indicates measured angle being cut. Have adjustability to compensate for various widths, thicknesses, and angles of molding, with solid clamping capabilities. Desired eye holes for bolting to a workbench. Mentioned being best for hand saw since pros use miter saws mostly. Light weight and small size desired to enable easy carrying, but built with rigid durable material that will not warp or deform, yet enable precise measurement. Possible challenge present from measuring/cutting 2D base board to 3D crown molding. Stated that there should be vast room for adjustability with up to 180 degrees of angle range. Indicated nailing should be done as last step, starting from the center of the work piece. Continually emphasized the key to making precise cuts and accuracy. Expressed interest in using the final jig and is willing to help along the design path.

Interview with do-it-yourselfer: Jon Heslop. 840 Prairie Ave Wilmington, OH 45177 09/03/13 He is a homeowner who is willing to try and do any DIY project. Greatly skilled with his hands and has done numerous personal home renovations, including installing molding. In discussing the method for holding the wall angle on the jig, he reiterated how important that the jig not move from the angle while being handled or possible dropped. Infinite adjustability at single pivot point was key to him to allow for half angles, through the use of a set-screw or degree hash marks. Precise cuts are key. Felt the jig should be able to measure and compensate for both the corner angle and the ceiling/wall angle for older homes. Encouraged to determine for hand saw or for miter saw. Recommended that the jig cut both pieces of molding without needing to be adjusted. Mentioned that it should sit flat for cutting. Should be useful, work well and look like it is engineered and well built. Encouraged targeting DIY audience for tool versus furniture makers. Keep affordable for DIY customers, low cost. The molding jig sparked his interest and he was very interested in seeing the designs when they are created. Felt that while unique, there could be a market for the device.

Milescraft Crown 45 Molding Cutting Jig, Model#1405 Supports three spring The Milescraft Crown 45 Molding Cutting Jig is a crown molding angles of molding. cutting jig which allows molding to be cut in “as seen” position. Cut angels based upon The jig supports 38, 45 and 52 degree angle moldings with any installer measurements. degree of cutting angle. Includes two spring angle finders. No assistance for Collapsible for easy storage and transport. measuring wall angle. Collapsible and http://www.northerntool lightweight. .com $30 USD 08/30/13

Crown Pro Supports spring angles The Crown Pro is a crown molding cutting jig which allows from 30-60 degrees. molding to be cut at the same angle to that as install. The jig Cuts angles based upon supports spring angles from 30 to 60 degrees, with any degree of installer measurements. cutting angle. The jig holds trim at exact angle required for No assistance for cutting. Includes an angle finder. measuring wall angle. http://www.kregtool.co No-slip feet for solid m positioning. 08/30/13 $30 USD

Cut-N-Crown Supports spring angles The Cut-N-Crown is a crown molding kit that supplies the tools of 30, 45, & 60 degrees. to measure and cut crown molding. The cutting jigs are set with Cuts angles based upon spring angles of 30, 45, or 52 degrees, with any degree of cutting installer measurements. angle. A manual degree finder is included to find the wall angle. Bulky and non- adjustable. http://www.cutncrown.c Requires careful om positioning of crown 08/30/13 during cutting. $150 USD

Bench Dog Crown Cut Molding Cutting Jig Cuts angles based upon The Bench Dog Crown Cut Molding Cutting Jig is a crown installer measurements. molding cutting jig holds molding at the install spring angle and Bulky and non- position. The cutting jig a wide variety of spring angles, with any collapsible. degree of cutting angle. Set-screws allow for secure placement of Requires careful molding guides at any spring angle. positioning of crown during cutting. http://www.benchdog.co Secure work holding. m $45 USD 08/30/13

12” Dual-Bevel Sliding Compound Miter Saw Cuts bevel angles from The 12” Dual-Bevel Sliding Compound Miter Saw is designed for 0 – 48 degrees. precise cutting of work pieces at up to 48 degrees. Incorporates Bulky and heavy eye holes for bench mounting. Dust channel diverts debris away (65lbs). from work piece. Digital angel readout in increments of 0.1 Accuracy to 0.1 degrees. Degrees. Integrated dust channel. http://www.milwaukeet Rigid cutting fence for ool.com holding material. 09/04/13 $649 USD

APPENDIX B - SURVEY

SPEED MOLDING JIG CUSTOMER SURVEY

The survey’s purpose is to gain customer preference on a new jig for cutting and installing molding (crown, baseboard, chair rail, etc). The Speed Molding Jig will allow measurement and cutting of required angles without math or knowledge of special trade techniques. The jig supports both the newest DIY members to long time professionals.

How important is each feature to you for the design of the Speed Molding Jig ? Please circle the appropriate answer. 1 = low importance 5 = high importance

Safety 1 2(1) 3(2) 4(2) 5(7) N/A (4.25) Durability 1 2 3 4(3) 5(9) N/A (4.74) Low Cost 1 2(2) 3(5) 4(4) 5(1) N/A (3.33) Ease of Operation 1 2 3(1) 4(5) 5(6) N/A (4.42) Ease of Maintenance 1 2 3(3) 4(8) 5(1) N/A (3.83) Precision 1 2 3 4(4) 5(8) N/A (4.67) Light Weight 1 2(5) 3(4) 4(2) 5(1) N/A (2.92) Small Size 1 2(5) 3(4) 4(3) 5 N/A (2.83) Single Person Operation 1 2 3(1) 4(5) 5(6) N/A (4.42)

How satisfied are you with the current Molding Cutting Jigs? Please circle the appropriate answer. 1 = very UNsatisfied 5 = very satisfied

Safety 1 2 3(1) 4(3) 5(2) N/A(6) (4.17) Durability 1 2 3(2) 4(1) 5(3) N/A(6) (4.17) Low Cost 1 2 3(5) 4(1) 5 N/A(6) (3.17) Ease of Operation 1 2 3(3) 4(2) 5(1) N/A(6) (3.67) Ease of Maintenance 1 2(1) 3(3) 4(1) 5(1) N/A(6) (3.33) Precision 1 2(1) 3(3) 4 5(2) N/A(6) (3.50) Light Weight 1 2 3(3) 4(3) 5 N/A(6) (3.50) Small Size 1 2 3(3) 4(3) 5 N/A(6) (3.50) Single Person Operation 1 2 3(1) 4(3) 5(2) N/A(6) (4.17)

How much would you be willing to pay for the Speed Molding Jig?

$10-$20 $20-$30 (2) $30-$40 (1) $40-$50 (3) $50-$60 (1) $60+ (5)

Thank you for your time.

APPENDIX C - QFD

APPENDIX D - OBJECTIVES

Objectives Based on the survey, the product objectives are the list of features that are taken into considerations. The following is a list of product objectives and how they will be achieved or measured to ensure that the goal of the project was met.

11. Durability (15%) a. Built from aluminum with all bolts torqued to spec or single piece machined b. All machined components greater then 1/8 inch thick c. Wear surfaces covered in appropriate wear material 12. Ease of Operation (12%) a. One step angle locking b. Labels and numbers with minimum 16pt font c. Guides remain rigid (flexure under 3/16 inch) during cutting 13. Operation by One Person (12%) a. Jig can be used for measuring wall angle or cutting on a bench by one person b. Grip points for carrying and holding within ergo specifications c. Eye holes in corners for bench mounting 14. Sufficient Precision (12%) a. Molding “A” surface gap less then 1/16 inch on cut molding when installed b. Prototype built from aluminum c. Set-screw for locking and angle holding d. Saw guide for holding saw in cutting position e. Measures half (0.5) degree increments with one (1) degree numbers 15. Ease of Maintenance (11%) a. All components removable with single tool b. Cutting location open for dust removal 16. Light Weight (11%) a. Product (prototype) is less then seven (7) pounds 17. Safety (10%) a. Set-screws and hand components all ergonomically compliant b. Pinch points all labeled c. Rubber feet to limit movement during normal operation to under two (2) inches d. Guides hold saw from slipping toward off-hand (work piece holding hand) e. Radius or filleted edges 18. Affordable (10%) a. Meets or surpasses cost value as set by survey for manufacturing 19. Small in Size (8%) a. Able to fit in average two (2) cubic foot tool box/bag b. Can to be carried with one (1) hand 20. Flexibility (00%) a. Measures wall angles between 0 and 270 degrees (minimum) b. Can measures outside and inside corners c. Able to hold one (1) inch to six (6) inch wide molding

APPENDIX E - SCHEDULE

APPENDIX F - BUDGET

Materials, Components or Labor Forecasted Amounted Actual Amount

Raw Material $300.00 $28.20 Hardware $30.00 $65.25 Machining $200.00 $0.00 Printing $25.00 $0.00 Misc. Service/Parts $100.00 $7.16 Total $655.00 $100.61

APPENDIX G – DETAILED DRAWINGS

9 0.3

8.86 8.86

1/4"-20 Thread 3/16" Steel 15.35 STK OK

Laser Cut with DXF

UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN L.Rice 01/17/14 Speed Molding Jig TOLERANCES: FRACTIONAL 1/8in CHECKED TITLE: TWO PLACE DECIMAL 0.05 ENG APPR. THREE PLACE DECIMAL 0.005 MFG APPR. Left Side Base Q.A.

COMMENTS: Senior Design Project at MATERIAL University of Cincinnati College of SIZE DWG. NO. REV SolidWorks Student Edition. 1018 Steel Engineering and Applied Science. Created by Lucas Rice and advised by FINISH SD102 For Academic Use Only. Tumbled Dr. Laura Caldwell. A

DO NOT SCALE DRAWING SCALE: 1:3 WEIGHT: 3.47LBS SHEET 1 OF 1 5 4 3 2 1

3.00

0.29 3/16" Steel STK OK 6.45

9.00

1/4"-20 Thread Laser Cut with DXF

UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN L.Rice 01/17/14 Speed Molding Jig TOLERANCES: CHECKED FRACTIONAL 1/8in TITLE: TWO PLACE DECIMAL 0.05 ENG APPR. THREE PLACE DECIMAL 0.005 MFG APPR. Workpiece Table Q.A.

COMMENTS: Senior Design Project at MATERIAL University of Cincinnati College of SIZE DWG. NO. REV SolidWorks Student Edition. 1018 Steel Engineering and Applied Science. Created by Lucas Rice and advised by FINISH SD104 For Academic Use Only. Tumbled Dr. Laura Caldwell. A

DO NOT SCALE DRAWING SCALE: 1:3 WEIGHT: 2.64LBS SHEET 1 OF 1

5 4 3 2 1

0.500 0 1/4"-20 Thread 0.750 .2 1 1.000 0

0.375

0.188 0.500

0. UNLESS OTHERWISE SPECIFIED: NAME DATE 266 DIMENSIONS ARE IN INCHES DRAWN L.Rice 01/17/14 Speed Molding Jig 0.250 TOLERANCES: CHECKED TITLE: 0. FRACTIONAL 1/8in TWO PLACE DECIMAL 0.05 ENG APPR. 375 THREE PLACE DECIMAL 0.005 MFG APPR. Hinge Q.A.

COMMENTS: Senior Design Project at MATERIAL University of Cincinnati College of SIZE DWG. NO. REV SolidWorks Student Edition. 1018 Steel Engineering and Applied Science. Created by Lucas Rice and advised by FINISH SD105 For Academic Use Only. Machined Dr. Laura Caldwell. A

DO NOT SCALE DRAWING SCALE: 2:1 WEIGHT: 0.06LBS SHEET 1 OF 1

5 4 3 2 1

3/16" Steel STK OK 4.36 3.50

1.00 3.50 Laser Cut with DXF

UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN L.Rice 01/14/14 Speed Molding Jig TOLERANCES: CHECKED FRACTIONAL 1/8in TITLE: TWO PLACE DECIMAL 0.05 ENG APPR. THREE PLACE DECIMAL 0.005 MFG APPR. Angle Gauge Q.A.

COMMENTS: Senior Design Project at MATERIAL University of Cincinnati College of SIZE DWG. NO. REV SolidWorks Student Edition. 1018 Steel Engineering and Applied Science. Created by Lucas Rice and advised by FINISH SD106 For Academic Use Only. Tumbled Dr. Laura Caldwell. A

DO NOT SCALE DRAWING SCALE: 1:1 WEIGHT: 0.43LBS SHEET 1 OF 1

5 4 3 2 1

9.54

3/16" Steel STK OK Laser Cut with DXF 2.00

0.26 UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN L.Rice 01/17/14 Speed Molding Jig TOLERANCES: CHECKED FRACTIONAL 1/8in TITLE: TWO PLACE DECIMAL 0.05 ENG APPR. THREE PLACE DECIMAL 0.005 MFG APPR. Extension Angle Slide Q.A.

COMMENTS: Senior Design Project at MATERIAL University of Cincinnati College of SIZE DWG. NO. REV SolidWorks Student Edition. 1018 Steel Engineering and Applied Science. Created by Lucas Rice and advised by FINISH SD108 For Academic Use Only. Tumbled Dr. Laura Caldwell. A

DO NOT SCALE DRAWING SCALE: 1:2 WEIGHT: 0.81LBS SHEET 1 OF 1

5 4 3 2 1

0 .7 5

8.00

3/16" Steel 12.93 STK OK

Laser cut with DXF

UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN L.Rice 01/14/14 Speed Molding Jig TOLERANCES: CHECKED FRACTIONAL 1/8in TITLE: TWO PLACE DECIMAL 0.05 ENG APPR. THREE PLACE DECIMAL 0.005 MFG APPR. Extension Q.A.

COMMENTS: Senior Design Project at MATERIAL University of Cincinnati College of SIZE DWG. NO. REV SolidWorks Student Edition. 1018 Steel Engineering and Applied Science. Created by Lucas Rice and advised by FINISH SD110 For Academic Use Only. Tumbled Dr. Laura Caldwell. A

DO NOT SCALE DRAWING SCALE: 1:3 WEIGHT: 1.63LBS SHEET 1 OF 1

5 4 3 2 1

8.87

0 8.87 .2 3/16" Steel 7 STK OK

Laser Cut with DXF

UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN L.Rice 01/17/14 Speed Molding Jig TOLERANCES: CHECKED FRACTIONAL 1/8in TITLE: TWO PLACE DECIMAL 0.05 ENG APPR. THREE PLACE DECIMAL 0.005 MFG APPR. Right Side Base Q.A.

COMMENTS: Senior Design Project at MATERIAL University of Cincinnati College of SIZE DWG. NO. REV SolidWorks Student Edition. 1018 Steel Engineering and Applied Science. Created by Lucas Rice and advised by FINISH SD201 For Academic Use Only. Tumbled Dr. Laura Caldwell. A

DO NOT SCALE DRAWING SCALE: 1:3 WEIGHT: 1.09 LBS SHEET 1 OF 1

5 4 3 2 1

3/8" 1/4" 3/8"

0.250"

3/16" Hex 1/4"-20 Thread

PART NUMBER 91251A535 http://www.mcmaster.com Black-Oxide Alloy Steel © 2008 McMaster-Carr Supply Company Socket Head Cap Screw Unless otherwise specified, dimensions are in inches. Information in this drawing is provided for reference only.

3/8" 1/4" 1 1/8"

0.25"

3/16" 1/4"-20 Thread Hex

3/4" 3/16" 3/4"

0.25"

1/4"-20 Thread

3/4" 3/16" 1/2"

0.25"

1/4"-20 Thread

APPENDIX H – BILL OF MATERIALS

Item No. Part Number Description QTY. 1 SD102 Left Side Base 1 2 SD103 Hinge Bracket 1 3 SD104 Workpiece Table 1 4 SD105 Hinge 2 5 SD106 Angle Gauge 1 6 SD107 Extension 1 7 SD108 Extension Angle Slide 1 8 SD201 Right Side Base 1 9 SD202 Saw Guide – Rear 2 10 SD203 Saw Guide Lock 1 11 SD204 Saw Guide – Front 2 12 91251A535 ¼”-20 3/8” Hex Screw 6 13 91251A560 ¼”-20 1-1/8” Hex Screw 2 14 91746A412 ¼”-20 3/4” Thumb Screw 3 15 91746A421 ¼”-20 1/2” Thumb Screw 1