Working Details

• Phase  1: Requirements & Budget Alignment – Engaged with the client to quantify throughput, cavity geometry, and lifetime expectations while working within a tightly capped capital budget typical of OEM confectionery suppliers. Cost‑down levers; including modular sub‑assemblies and local material sourcing; were identified early.

• Phase  2: Cam Profile Formulation – Devised incremental segment hole punches via SVAJ analysis to shape a Critical Extreme Position (CEP) cam. The profile orchestrates a complete punch cycle across 21 active slots, while the complementary 21 slots reset the mechanism for continuous syrup intake, preventing cavity overfill.

• Phase 3: Structural Design & Stress Audit – Modelled the 42‑segment barrel, cam, and slot punches in SolidWorks, then validated torsion and hoop stresses in Altair. A sand‑cast aluminium prototype confirmed manufacturability; final tooling used investment‑cast 316 L stainless for corrosion resistance and dimensional fidelity.

• Phase  4 : Precision Machining & Modular Assembly – Individual punches were carved on VMC, HMC, and CNC lathes directly from G‑code, adhering to DFA/DFM principles for rapid change‑out. The 500 mm‑long barrel, weighing ~38 kg, assembles with keyed modules to facilitate maintenance and future cavity redesigns.

Factory acceptance trials demonstrated consistent mould fill, clean ejection, and dimensional tolerance within ±0.05 mm over 16‑hour endurance runs, validating both CEP timing and mechanical robustness.