Smartphone Manufacturing Plant to

Setup in India by 2026

to Make Phones
that Do Not Require Charging ?
A Research Initiative by Namoona 3D Labs

Nikhil Chaitanya
Founder and CEO
 A Government of India Initiative
• Aatma Nirbhar Bharat
• Skill India
• Startup India
• Make In India
• Swatch Bharat
 About Me –
A. Nikhil Chaitanya
Experience
• Systems Engineer in Infosys Hyderabad Global DC (August 2021 – Present)
• Reviewer in Journal of Ocean Engineering UK (May – July 2021)
• Online Tutor on YouTube (April 2020-Present)
• Packaging Engineer in TCS Pune (Jan-June 2018)
• Product Development Trainee in TCS Trivandrum (Jul-Dec 2017)
• Student Expert in Autodesk Fusion 360 (Jan-July 2016)

Education
• PhD (3D Printing) (2020-2023) from GITAM University, Vizag
• M.Tech Machine Design (2018-2020) from Andhra University, Vizag
• B.Tech Mechanical Engineering (2013-2017) from GITAM University Vizag
 Autodesk Innovation Centre,
Dayananda Sagar University, Bangalore

Officially Trained by Autodesk

on Fusion 360 on 5-Day Training on
“Future of Making Things” in
January 2016
TCS New Product Development Centre - Trivandrum

I was part of TCS

Trivandrum
New Product
Development (NPD) Wing
and I got trained in 3D
Printing and Product
Development in 2017
One Among Top 5 Winners of Fusion 360 Design Now among 100+
participants– Held by Autodesk in GITAM Vizag
 Case Study: Applying Value Engineering
to a typical design of toy car

*Illustrations shown in this presentation are for educational only and could differ slightly from the actual toy car design from the original manufacturer
Tear Down Representation of existing design
 Functional Analysis
Part Part Name Qty Function
ID
1 Car body X1 Give Aesthetic look to the toy

2 DC Motor X2 Provide Power to rear axle and steering mechanism

3 Wheel Rims X4 Provide strength and stiffness to the wheel
4 Rubber tyres X4 Provide surface grip and friction to drive toy
5 Chassis X1 Provide structure to mount drive-train ,battery, switch, PCB and steering mechanism

6 Printed Circuit X1 Provide electronic control circuit

Board
7 Rear Axle X1 Transmit power to rear wheels
8 Bevel Gear X1 Change direction of power from motor to axle
9 Motor Clamp X1 Secure the motors in place firmly
10 Antenna X1 Receive signals from remote control
11 Steering Gear X1 Convert motor shaft movement into steering
12 Steering tie rod X1 Steer the front wheels left or right
 Functional Analysis continued…

Part Part Name Qty Function

ID
13 King pins X2 Connect tie rods to wheel rims while providing for steering axis
rotation
14 Steering Clamp X1 Secure the kingpins while allowing them to rotate
15 Switch X1 On/Off switch
16 Battery terminal X3 Connect battery terminals
contacts
17 Battery Cover X1 Cover batteries and prevent dirt ingress

18 Batteries X2 Supply voltage power

19 Bearings X2 Reduce friction, noise and shaft misalignments
20 Screws X 11 Fasten the parts
 Identify Parts for improvement

Part Interaction Table

1 2a 2b 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
5 5 5 X 5 5 5 5 5 5 5 5 5 5 5 5 5
X 3 3 3
9 9 X 9
13 13 X 13
11 X 11
10 X
8 8 X
20 20 20 20 20 X
18 X

Interested to reduce material Not interested to modify

Part ID : 2 – DC Motor 5 – Chassis 9 – Motor Clamp Cover 11 – Steering Gear 8 – Bevel Gear
 Objectives and Constraints for developing new clamps

Objectives
• Save plastic material wherever possible
• Reduce number of screws

Design Constraints Strength Constraints

• Motor should be clamped • Chassis should be strong in bending and torsion
firmly • Bosses > 5mm height need stiffeners
• Available space
• Battery box and PCB space
should not be modified
Heat Transfer Constraints Moulding Constraints
• Motor gets heated up during running and needs • Undercuts need to be avoided
ventilation • Fillets should be provided
• Cross-sections should change gradually
 New Improved Design of toy car
Existing Design New Improved Design of clamps

Motor Clamp

Chassis
Steering Clamp
New Improved Design of clamps

Highlights
• Less plastic material used
• Bosses reduced from 4 to 2
• Screws reduced from 6 to 4
• Stiffer motor clamps
• Most parts are left unmodified
so that existing parts can be used

Downsides
• New tooling for modified
parts
• Development and testing costs
 Summary of improvement

Parameter Existing Design New Design Material Saving

Plastic material used for 180*60*2 + 4x3.14/4*(62- 180*60*2 + 2x3.14/4*(62-42)*25 + 2%
chassis (in mm3) 42)*25 + 2x2*180*1
2x(2*20*1*2+2*20*1*3) =
23571 mm3 (approx.) = 23105 mm3(approx.)

Plastic material Volume Motor Clamp Rear Motor Clamp 38 %

used for clamps (in 140*40*2 + 4x22*8*2 – 40*50*2 + 12*40*2 – 2x6*6*4 –
mm3) 2x2*3.14*/4*102- 12*2*15
9x2*3.14/4*42 = 12068 mm3 = 4312 mm3(approx.)
(approx.) Steering cum front motor clamp
Steering Clamp 60*30*2 – 4x1/2*15*10*2 +
60*30*2 – 4x1/2*15*10*2 + 15*40*2 + 40*12*4 – 12*2*15 =
15*40*2 = 4200 mm3(approx.) 5760 mm3(approx.)
Number of Screws for 6 4 33%
clamps
Why 3D Printing ?
Cost-Volume Diagram for Plastic Toys
(Of size 250mm x150mm x100mm)
 Areas / Domains / Opportunities
under 3D Printing
1. Automotive
2. Aerospace
3. Civil/Construction
4. Toys
5. Consumer Electronics
6. Jewelry
7. Packaging
8. Bio Mechanical / Bio Medical
 Challenges in 3D Printing
Printing Stage
Design Stage  Machine Model Specifications
 File Types  Process
 Geometry  Build Volume
 Method of Printing
Cost Estimation and Reduction  Machine Tolerance
 Size
 Infill and strength optimisation
Printer Settings
 Minimum Layer Height
 Process
 Infill/Supports/Adhesion
Process limitations Materials (PLA/ABS/TPU/PETG)
 SLA/FDM/DLP/SLS/SLM  Strength
 Tolerance, surface finish and strength  Stiffness
 Thermal Properties
 Electrical Properties
 Fused Deposition Modeling (FDM),
also known as Fused Filament Fabrication (FFF)
Some of my Designs made while in my B.Tech in GITAM
Wind Tunnel Testing of Formula 1 Car – Sauber F1 Team (2013)

IMAGE Courtesy: SAUBER F1 Team

3D Printed Custom Made Phone Case
 3D Printed Models for Wind Tunnel Testing

University of Applied Sciences, Laboratory for Rapid Prototyping, Gengenbach, Germany

 Tools Needed to get Started
• Autodesk Fusion 360 (Free for Students)
• Ultimaker Cura (Free for all)
• FDM 3D Printer (Available at our Facility in Vizag)
• Laptop/Desktop with 8 GB RAM, 2.5 MBPS Internet
speed
• Motivation and Dedication to Learn
Research Areas (R&D) in 3D Printing for
Mechanical/ECE/Electrical Engineers
• Plastic manufacturing
• 3D Printing Materials
• Rapid Moulding techniques
• Sensor data capturing methods
• Conductive filaments
 Research Phase-1 Reviews – 2020-2021 Admitted year

Condition Monitoring of 3D Printing Process

Using Evolutionary Intelligence
Regd. No: 122060802003
ANGAJALA NIKHIL CHAITANYA
Part-Time PhD Scholar

Under Supervision of
Dr. Balla Srinivasa Prasad
And Co-supervision
of Dr. R Rajeswar Reddy

Dept. of Mechanical Engineering, GITAM University, Visakhapatnam

 4 Broad Areas of 3D printing are studied for opportunities

Area 1 - Stronger 3D print materials Area 2 – Electrical Conductive materials

Area 3 – Rapid Mould Tooling Area 4 – Condition Monitoring

Topic-Scope Matrix for Applications & Research (R&D)
Area Explored in 3D Existing knowledge Scope identified for
printing for Applications Further Research
(Scale 0-10) (Scale 0-10)
Low-High Low-High
(A) (B)

Stronger 3D
printing Moderate (4) High (8) Research and Applications
materials
Conductive
Low (2) High (8) Research Only
Materials
Mould Tooling Moderate (6) Moderate (6) Applications Only
3D printing
process Low (3) High (7) Research and Applications
monitoring
 Neural Network
Input Layer
Intermediate
Bed Temperature Layers Output Layer

Nozzle Temperature Machine Stop

Voltage Electrical Failure
Current Too much speed
Printing Speed Bed/head Overheat
Bed Vibration Too cold bed/nozzle
Head Vibration
It takes 24-36 months for a company It ONLY takes 6-8 months for a
of 100 employees to build a new STARTUP of just 1 employee to
product and release that into the build a new product and release
market. Reason ?
5 Sketch Designers needed
that into the market. Reason ?
8 CAD Designers needed
No meetings needed between teams
10 Mechanical Engineers needed
No approvals needed between leads
6 Electrical Engineers needed
No presentations needed with managers
12 Electronics Engineers needed
No money needed for offices
12 Developers needed
No time needed for travel
5 HR managers needed
12 New Hires needed
20 Layman Workers needed It is only about thinking and
2 Journalists needed executing in your way
4 Accountants needed
3 Directors needed
1 CEO needed
 How Smartphones
That Do Not Require Charging
are possible?
• Solar Power Banks and 2-Way Power modules similar to Casio Calculators
• Piezzo Electric Actuators under touch screen that generate electric pulses !
• Peltier and Seebek effect based power generation built into the charging devise
• Place the charging pad near a gas stove/candle flame and it gets charged !
• Revolutionary Power Saver Mode for Emergencies (Built into Android)
• Extreme Power Saver lasts your phone for making “Calls and message” for 30 days
!
 Thank You
• “People who are crazy enough to think that
they can change the world are the ones who
actually do” – Steve Jobs, CEO of Apple