1. Documentation of the MMM
Ice Crystal Replicator
Julian Claudio
University of Colorado at Boulder, Mechanical Engineering
Summer Undergraduate Program for Engineering Research (SUPER)
August 10th, 2016

2. Background
The goal of this project was to document and design
the Ice Crystal Replicator instrument that MMM has been
using since the 1990s but for which they never had CAD
models or drawings. The instrument needed to be modified to
adjust to a new film size and a larger motor for a team of
German scientists working with MMM scientist Carl Schmitt.

3. Function

4. Methods
The process can be broken down into simple steps:
(2 weeks) – Design/Drawing
• Part Design
• Assembly of Parts
• Part Drawings
(4 weeks) – Review
• Design Review (Customer)
• Redline Process
(4 days) – Fabrication
(2 days) – Testing

5. Engineering
• 35 parts, 5 sub assemblies, 1 final assembly

6. Engineering
Important mathematical calculations for the project:
• Thermal expansion
• Arc length
• Elastomer compression ratio

7. Engineering
• Thermal Expansion
• ∆d = d0*α*∆T
• Important to consider
since instrument
operates at -40 ˚C
• Prevent jamming
• Prevent breaking glass

8. Engineering
• Arc length
• S = r*Θ
• The drive teeth needed
to move the film through
the instrument.

9. Engineering
• Compression ratio
•
𝑑 𝑐𝑜𝑛𝑡𝑎𝑐𝑡
−𝐼𝐷𝑜 𝑟𝑖𝑛𝑔
𝑤 𝑜 𝑟𝑖𝑛𝑔
• A pressure seal is
required to
move the
chloroform
through the
tube

10. Engineering
Materials:
• Aluminum
• Delrin
• Polycarbonate
• PVC
• Brass
• Beryllium Copper

11. Engineering
Final Product CAD Model

12. Challenges
• Considering the tolerances of the existing
instrument

13. Challenges
• Didn’t originally know function of the
instrument

14. Challenges
• Designing and drawing for machining, tolerances on
the engineering drawings were evaluated for
functionality and manufacturability.

15. Challenges
• Glass tubes; thermal compression was a large factor, o-ring
groove and cap diameter had to seal but not break the glass
at low temperatures.

16. Lessons Learned
• Attention to detail is key in engineering.
• Never assume you’re completely done until
testing is complete.
• Learned appropriate tolerancing and
designing for manufacturing.
• Always buy quality materials if you can help it.

17. Special Thanks
• Jim Ranson – Mentor/DFS Manager
• Karl Schwenz – Machine Shop Supervisor
• Instrument Makers
• Chris Burghart & Nick Potts – SUPER Cooridnators

18. Questions?