Team Members & Role:

Conor O’Neil: Team Lead

Nicholas Planzo: Analysis Lead

Gabe Nissenbaum: Design Lead

Adrian DeMichele: Fabrication Lead

Jacob Mastalerz: Evaluation Lead

Abstract: The HIT-NOT is a proximity detection system used in warehouses that alert workers to nearby forklifts. The Packaging Corporation of America (PCA) utilizes the HIT-NOT in its facility to ensure the safety of its workers. The HIT-NOT device is worn by workers and emits a noise when a forklift is nearby. With the current soft case provided by HIT-NOT, there are difficulties making successful contact with the magnetic charger. This prevents the devices from charging, making them unavailable when workers need them. The current HIT-NOT products do not align with the PCA’s need for the device to charge while in a holster. HIT-NOT has a purchasable charging station, but the HIT-NOT device must be removed from its holster before insertion. Additionally, HIT-NOT’s charging base is costly and impractical, totaling $449. To resolve this issue, a 3D-printed holster and base combination was designed that allows the HIT-NOT to charge while in the holster using the HIT-NOT-provided magnetic charger cords. A design using Polymaker PolyLite PLA filament was chosen for its excellent printing characteristics, availability, and strength. Using press-fit designs to secure the HIT-NOT into the holster as well as the charging cord into the base allows for easy, efficient, and cost-effective assembly. The holster was outfitted with a metal belt clip and fastening hardware to ensure reliability in the clip assembly and allowed the team to focus more on the 3D-printed parts. The combined units optimize material usage and characteristics of 3D printing to create a solution to PCA’s presented problems.

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