Alex Murchison
Mechanical Engineering Student
Engineering Design
My Initial thoughts
Before starting the screwdriver project, I mainly expected it to focus on basic machining and shaping operations. Once the project began, I realized there was much more involved in the manufacturing process, especially when considering durability, ergonomics, surface finish quality, and production efficiency. Working through the forged and injection molded portions of the project helped me better understand how different manufacturing methods are selected depending on cost, production volume, and intended product use. The project also gave me more experience with machining operations, finishing techniques, and the importance of process planning in real-world manufacturing.
Enigneering Projects
CNC Machined Screwdriver Manufacturing Process
METHODOLOGY / CHALLENGE / SOLUTION
Forged & Injection Molded Screwdriver Design Analysis
This project focused on the design, manufacturing, and production analysis of both a forged screwdriver and an injection molded screwdriver handle. The goal of the project was to better understand how different manufacturing methods impact product strength, ergonomics, production cost, surface finish quality, and overall manufacturing efficiency in both low-volume and large-scale production environments.
At the start of the project, the screwdriver appeared to be a relatively straightforward hand tool, but as the manufacturing process progressed it became clear how much engineering, planning, and precision go into even a simple everyday product. The project required analyzing material selection, machining operations, tooling requirements, finishing processes, and manufacturing workflow while also considering how the product would perform during long-term use.
The forged screwdriver portion of the project involved several machining and finishing operations including turning, knurling, grinding, sanding, deburring, and heat treatment processes. These operations were used to improve dimensional accuracy, durability, grip quality, and overall product appearance. Attention was also placed on process order and manufacturing efficiency to better understand how production methods affect machining time and final part quality.
The injection molded screwdriver handle portion of the project focused on high-volume manufacturing methods and ergonomic product design. This section demonstrated how injection molding can improve manufacturing consistency, reduce production cost, and increase production speed while creating a comfortable and repeatable final product. Consideration was also given to mold design, manufacturability, and how product geometry impacts the molding process.
One of the most valuable parts of this project was learning how engineering decisions directly influence manufacturing cost, tooling complexity, production speed, and product performance. The project helped strengthen my understanding of machining operations, process planning, manufacturing analysis, and the relationship between engineering design and real-world production methods commonly used throughout industry.
Designed Through Manufacturing Thinking
This forged screwdriver project focused on the full manufacturing process behind creating a durable hand tool, from material preparation and machining to finishing and final detailing. The project emphasized manufacturing methods, process planning, and precision while balancing both functionality and appearance.
The build involved CNC lathe operations, shaping and profiling features, surface finishing, and refining the screwdriver tip geometry to meet dimensional and functional requirements. Throughout the project, I worked through machining strategy, tolerancing, tooling considerations, and production-focused decision-making.
This project helped expand my understanding of machining processes, fabrication workflows, and the direct connection between engineering design and manufacturing efficiency and product performance. It also strengthened my hands-on experience with shop practices, process planning, and detail-oriented manufacturing work.