Novel Design of Modular laptop Cooling Stand

Academic

December 2024

Boulder

We developed an ergonomic laptop stand with a modular cooling pad to enhance usability, ventilation, and manufacturing efficiency.
Benchmarking and teardown studies informed our initial design, modeled and optimized in SolidWorks.
We reduced the original 35-part assembly to fewer key components, achieving over 10–15% part count reduction.
A detailed DFA analysis improved practical efficiency and reduced assembly complexity by simplifying the frame and cooling pad structure.
Material optimization using Ashby charts led to strategic selection of ABS, aluminum, and EVA foam for performance and sustainability.
We evaluated alternate materials (e.g., TPE, magnesium, stainless steel) for trade-offs in strength, cost, and manufacturability.
Injection molding, die casting, and compression molding were chosen to match materials with scalable processes.
Our economic analysis estimated a break-even point at 20,781 units, with significant savings from material and labor cost optimization.
Process refinement and design consolidation resulted in an estimated 20% reduction in assembly time and better error-proofing.
This DFMA project balances product performance, manufacturing feasibility, and economic viability in a well-rounded consumer design.

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