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Structural Analysis and Manufacturing Process for a Stapler Cover using CREO Parametric

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Introduction: Performing Structural Analysis on a Model using CREO FEA Consulting Services

By using the CREO platform different FEA consulting services can be performed including structural, thermal as well as modal analysis on different parts, models, or assemblies. In this project, a structural analysis of a model can be performed. All of the processes can be done after making the design of a part of the stapler cover and then it will be analysed in the CREO Parametric as static stress analysis. Different types of structural analysis can be performed through the CREO parametric where it is capable of including the real-time analysis, stress, strain, deformation optimization process of the topology, and finally measuring lattice surfaces. The CREO parametric enables the analysts for analysing as well as confirming the results along with actual performance regarding the parts design model or assembly. It is considered as a tool that can be easily integrated within the proper design workspace where editing as well as analysing will be very easy.

On the other hand, different types of models can be produced for use in the manufacturing process of the civil, automobile, electrical, medical sector, and many more. In this project, a model will be designed as well as moulding with manufacturing techniques in terms of performing the static stress analysis and understanding the behaviours as well as total deformation on the model as well as different manufacturing processes. In this regard different activities can be maintained to perform the static stress analysis which can show the materials section, mesh generation, boundary generation, applying the pressure, and finally obtaining the actual outcomes.

Aim & Objectives

The entire project is focused on the FEA analysis of a basic part model which can be performed through the CREO parametric platform and it is considered as a designing as well as a simulation tool to observe the actual results on the entire model (Gouveia et al. 2017). The simulation approach of the basic stapler cover can be done by performing different types of analysis which can show the total deformation, deflection, safety factor of the particular laid condition, and finally the static stress analysis. In terms of meeting with the actual focus of the project different types of objectives can be generated that are provided in the below section:

  • To select the appropriate material with its characteristics.
  • To observe the actual stress behaviours on the model.
  • For understanding the total deformation on the part model.
  • To understand the manufacturing process which is done through the simulation approach of a model.
  • To understand the total deflection of the item as well as the safety factor of the specific load condition.
  • For understanding the different moulding processes as well as manufacturing techniques (thejpd.org, 2021).

Part Design Steps

To create the CAD modelling of the part, at first, I have to open the CREO Parametric. For creating a new part at first it has to set the working directory in a folder and when the part will be created it will be saved in that folder. Then it has to select the new from file option to open a new page. It has to provide “part 1” as a part name. Then has to clear the user default template check box. Finally, click ok where new file options will be open. And also, I have to select the "mmns_part_solid" then click ok. Then it has to create the rectangular two-dimensional shape like the stapler cover outer line and then it will extrude the sketch to create the 3D geometry. For specifying the actual plane of the sketch, the model tree can be generated by the datum plane top (Mikolajczyket al. 2019). Then I have to click the extrude feature to provide a shape to the model. The computer-aided manufacturing process can be implemented to make a sustainable design process of a part design as well as its manufacturing as well as the production process. Generally, the CAM process is considered as the use of software as well as computer-controlled machinery for automating the entire manufacturing process of a proposed model. The software will be able to tell a machine how to make a product with the generation of a toolpath. The machines will be able to turn the raw materials into finished products. After designing the part model in the Computer-Aided Design it can be loaded into CAM. It is a traditional process done through the exportation of the CAD file and then it will be imported into the CAM software.

Considering the CREO platform there are CAD & CAM both that exist in a similar platform. Once the CAD model can be finished then it will be imported into CAM on the other hand the software can initiate preparing the model related to the machining process. I have observed that machining acts as a controlled process regarding the transformation of raw materials regarding machining. It can transform the raw materials into a defined shape by auctions including cutting, drilling, moulding as well as boring. In this regard, the G-code is very easy for understanding the actual format. While the G-code can be loaded into the machine and the operator hits the start option then the entire job can be finished. Different manufacturing centres are capable of running the different computed-based numerical control or CNC for producing the different parts. The actual process of programming a CNC machine can perform the specific action which is also known as the CNC machine. Before initiating the CNC machines, the centres of the manufacturing can be operated through Machinist veterans (Yilmaz et al. 2017). After that, the touch of computers, as well as the automation process, can be followed up by loading an appropriate program, inserting the different types of raw materials, and then unloading the actual products.

Mould Design Considerations

For this project, the injection moulding process is selected and different steps exist in terms of the injection moulding process which can be considered carefully. It can apply during the analysis of design apart, creation of tools, and finally the efficient production of plastic-based products.

  • Step 1: The first step is generally known as the mould closes where the injection moulding cycle times initiates while mould closes.
  • Step 2: The second step is known as the injection where the heated plastic can be injected into the mould. As there is melt entered into the mould it can be displaced air escapes by using vents within the actual pins of injection and also the parting line (Mikolajczyket al. 2018). On the other hand, the runner, gate as well as vent design are essential in terms of ensuring that mould is properly filled up.
  • Step 3: The third step is also known as the cooling process. If the mould is filled up properly there are major requirements of cooling the extent of time required for hardening the entire materials. The actual time of cooling relies on the types of resin that have been used as well as the thickness of the parts. It can be designed by internal colouring as well as lines of heating.
  • Step 4: The fourth step is the plasticizing process of the resin and while the parts are kept for cooling a barrel screw retracts as well as draws the latest designs made of plastics into a barrel with a material hopper (Andrade et al. 2018). On the other hand, the heater brand is capable of maintaining the required barrel temperature regarding the actual type of resin being used.
  • Step 5: This step is known as the ejection process and in this step, the mould opens and the ejector rod can move the pins of the ejector to the forward direction.
  • Step 6: The last or final step is based on removing the runner as well as packaging. In this regard, it can be said that although the injection moulding and its cycle of a machine end in the previous step so the process will continue.

Related Issues of Injection Moulding

There are different types of problems that have arisen in the injection moulding process. These generally flow lines, sink marks, vacuum voids, surface declamations, and many more. In this case, two problems along with fixing procedures are described in this section:

  • Flow Lines

These issues are generally caused for flow areas where the molten plastics pass through the mould and change the actual thickness of mould walls. It is also caused by the speed of injection which is generally low (Tanveer et al. 2021). In this case, it can be fixed by increasing the injection speed as well as pressure where the activities can be filled properly. And also increasing the molten temperature can be fixed.

  • Sink Marks

It generally occurs during the cooling time where the mechanism is improper and the plastic is not properly cooled down when it is inside the mould. It is also caused by issues in the pressure within the cavity or major heat. It can be fixed through reduction of mould temperature, growing up the holding pressure, and finally the time for cooling.

Mould Manufacturing Considerations

  • CAD & CAM

After finding the complete design in the CREO platform it can be loaded into the CAM platform. It can be done by exporting the CAD file as well as importing it into the CAM software. After importing the CREO file the software will be capable of creating the model for machining (Abdullah et al. 2018). Through the transformation of raw materials, it will be able to provide a defined shape by different actions like cutting, drilling, and finally the boring. In this case, the information related to design can be converted into G-code which is also the machine language for different actions such as speed, feed rate, and finally the coolants.

  • CNC Process

After finishing the generation of G-code it will be applied for Computer Numerical Control machines for producing the actual parts. These processes regarding programming a CNC machine can be purchased for performing the particular action related to the proposed product.

  • Water, Plasma & Laser Cutting

For manufacturing the entire product, it has to use the precise laser, high-pressure water, and also a plasma torch in terms of performing the controlled cut as well as engraved finish. In this regard, the manual engraving process may take around several months for completing by hand but through this process, the entire work can be finished within a few hours (Eid et al. 2019). On the other hand, the plasma cutters are too handy to cut by electrically conductive components or materials such as metal (iop.org, 2018).


From the above project, it can be concluded that I have proposed a product that can be designed by the CREO platform and it is also an effective platform in terms of the manufacturing and production process. For this project, I have set a goal along with different objectives like designing and manufacturing approaches to a particular product. I have studied different designing approaches by the CAD platform as well as CAM platform. On the other hand, I have also understood the moulding process which can be used in the proposed project. In this project, I have discussed injection moulding along with its issues at the time of moulding along with fixtures. Finally, I have discussed the manufacturing process where I will use the CAD and CAM platforms like CREO and then import the model into the CAM platform. And generating the G-code can be implemented for the CNC process to produce the actual products.



Abdullah, A., Muhammed, F., Zheng, B. and Liu, Y., 2018. An overview of computer aided design/computer aided manufacturing (CAD/CAM) in restorative dentistry. Journal of Dental Materials and Techniques, 7(1), pp.1-10.

Andrade, J.P., Stona, D., Bittencourt, H.R., Borges, G.A., Burnett, L.H. and Spohr, A.M., 2018. Effect of different computer-aided design/computer-aided manufacturing (CAD/CAM) materials and thicknesses on the fracture resistance of occlusal veneers. Operative dentistry, 43(5), pp.539-548.

Eid, R., Juloski, J., Ounsi, H., Silwaidi, M., Ferrari, M. and Salameh, Z., 2019. Fracture resistance and failure pattern of endodontically treated teeth restored with computer-aided design/computer-aided manufacturing post and cores: A pilot study. Journal of Contemporary Dental Practice, 20(1), pp.56-63.

Gouveia, P.F., Schabbach, L.M., Souza, J.C.M., Henriques, B., Labrincha, J.A., Silva, F.S., Fredel, M.C. and Mesquita-Guimarães, J., 2017. New perspectives for recycling dental zirconia waste resulting from CAD/CAM manufacturing process. Journal of cleaner production, 152, pp.454-463.

Mikolajczyk, T., Latos, H., Paczkowski, T., Pimenov, D.Y. and Szynka, T., 2018. Using CAD CAM system for manufacturing of innovative cutting tool. Procedia Manufacturing, 22, pp.160-165.

Mikolajczyk, T., Malinowski, T., Moldovan, L., Fuwen, H., Paczkowski, T. and Ciobanu, I., 2019. CAD CAM system for manufacturing innovative hybrid design using 3D printing. Procedia Manufacturing, 32, pp.22-28.

Tanveer, W., Ridwan-Pramana, A., Molinero-Mourelle, P., Koolstra, J.H. and Forouzanfar, T., 2021. Systematic Review of Clinical Applications of CAD/CAM Technology for Craniofacial Implants Placement and Manufacturing of Nasal Prostheses. International journal of environmental research and public health, 18(7), p.3756.

Yilmaz, B., Azak, A.N., Alp, G. and Ek?i, H., 2017. Use of CAD-CAM technology for the fabrication of complete dentures: An alternative technique. The Journal of prosthetic dentistry, 118(2), pp.140-143.

Online Articles

thejpd.org, 2021, CAD-CAM cobalt-chromium surgical template for static

computer-aided implant surgery: A dental technique, Available at: https://www.thejpd.org/article/S0022-3913(19)30295-1/pdf [Accessed on 21.06.2021]

iop.org, 2018, Multimedia Image Technology and Computer Aided

Manufacturing Engineering Analysis, Available at: https://iopscience.iop.org/article/10.1088/1757-899X/317/1/012046/pdf [Accessed on 21.06.2021]

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