Our team was tasked with creating and comparing two methods of prototyping the LUCIA Cyst Models. The two methods we were comparing were 3D printing with PLA and Polyurethane casting.

3D Printed Models:

1. We used the Bambu printer and the provided .STL files for the LUCIA cyst models to 3D print.
2. We then removed the supports that were on the models and sanded the 4 pieces to prepare them for painting.
3. We used acrylic paint to paint the models as close to the original LUCIA models as possible. This part had some iterations as we needed to color match the paint using pink, red, white, and yellow.
4. We finally spray painted the 4 models with a clear glossy coat. 

Polyurethane Models:

1. We created a box to house the cysts in TinkerCAD with drop angles. The four cyst models were integrated within the box using solidworks. This created the positive to create a negative silicone mold. This was printed with PLA on the Bambu printer.
2. After the box was printed, we were able to pour the silicone into the box. We calculated that we would need 300 mL of silicone to fill the box and therefore mixed 150 mL each of Part A and Part B.
3. Once the silicone cured, we removed the mold using a scalpel and flathead screwdriver to get a clean negative silicone mold.
4. We then poured polyurethane into the negative molds. We mixed Part A and Part B of the polyurethane for 1 minute and used the remaining 2 minutes of the pot life to pour the mixture into the molds. The polyurethane cured very quickly and turned fully white within 10 minutes.
5. We demolded the models and used sandpaper to post-process. At this point they were ready for acrylic painting once again. These took more iterations to get a good color-match as it dried much darker compared to the PLA.
6. Once the paint was dried, we applied a coat of clear glossy spray paint to match the finish of the original LUCIA models.
7. Final Models:
   

Cost Analysis:

Cost Type	Cost	Price	Source	Quantity	Total
Materials	PLA Filament	$25.99/ 1 kg	amazon.com	0.2 kg	$5.20
	Silicon	$31.42/500 mL	amazon.com	400 mL	$25.14
	Polyurethane Part A + Part B	$25.09 /1 pint	amazon.com	80 ml	$4.27
	Acrylic Paint (24 colors) + Paint Brushes	$25.99 – ($0.54/fl oz)	amazon.com	2 fl oz	$1.08
	Gloss Spray Paint	$5.98 per 12 oz can	Home Depot	0.25 oz	$0.12
	Plastic Cups	$14.99 for 25	amazon.com	4	$2.40
	Popsickle sticks	$4.98 for 100	amazon.com	5	$0.25
	Ruler	$1.96 for 1	amazon.com	1	$1.96
Labor	Prototyping engineer	$36/hour	ziprecruiter.com	2 hours	$72
	3D Printing Operator	$23/hour	ziprecruiter.com	3 hours	$57
Total					$169.42

Feasibility for Mass Production

Number of products	3D Printing	Mold Casting ( Silicon + Polyurethane)
50	Time: Much Faster Quality: Higher Cost: $0.70 for 4 cervixes. $0.175 for 1 cervix print $0.175*50 = $8.75 total to print 50 cervixes	Time: Slower  Quality: Lower Cost: $2.18 for the 3d printed box +  $4.27 for 4 Cervixes + $25.14 for silicon box = $31.59 $7.90 per 1 cervix $7.90 * 50 = $394.875 total to print 50 cervixes
100	Time: Much Faster Quality: Higher Cost: $0.70 for 4 cervixes. $0.70*25=$17.50 total for 100 cervixes	Time: Slower  Quality: Lower Cost: $4.27 for 4 Cervixes $4.27*25=$106.75 total for 100 cervixes
1000	Time: Much Faster Quality: Higher Cost: $0.70 for 4 cervixes. $0.175 for 1 cervix print = $175 total for 1000 cervixes	Time: Slower  Quality: Lower Cost: $4.27 for 4 Cervixes $7.90 x 1000 = $7900 total for 1000 cervixes

Assumptions made: 

1. 3D printer is already purchased/access to a 3D printer is available 
2. There is no time constraint or deadline for creating the number of products 
3. Cost of creating 4 cervixes with 3D printing is $0.70 
4. Cost of creating 4 cervixes with Polyurethane casting is $31.59 (first time only and includes the 3D printed box, silicone, and polyurethane) 
   1. Cost of creating 4 cervixes with Polyurethane is $4.27 every time following the first 
   2. Assuming that we only make the 3D printed box and silicone mold once for all products made (50-1000)

From understanding the cost analysis and the process needed for both methods, we can conclude that the 3D printing method would be easier in terms of scalability. The 3D printer allows for efficient replication of the models and it overall cheaper to produce at a larger scale. The polyurethane requires extra materials and labor to produce and will be costly to scale up. Lastly, the 3D printed models also had a smoother and cleaner finish making them look better and matched the original models.

Clean Table: