We designed a simplified notching machine for CLN of South Florida to create V-shaped notches in trim cap material used on commercial signs. The trim cap, composed of flexible plastic with an aluminum core, requires precise notches to bend smoothly around curved surfaces and raised lettering. CLN’s existing tool, while functional, uses an overly complex mechanism featuring a large rotating blade that descends vertically, contacts the material, and rocks back and forth to cut each notch. This design incorporates excessive moving parts, increasing manufacturing costs, setup time, maintenance requirements, and susceptibility to mechanical failure.
Our objective was to develop a simpler, more affordable solution that maintained the same notch quality while improving operational speed and preserving cutting accuracy. We designed and built a mechanism using a sharpened V-shaped steel blade that presses straight down through the plastic to form each notch, then retracts to allow material repositioning for the next cut. This approach eliminates unnecessary motion and significantly reduces the total part count.
We conducted testing focused on notch quality, consistency, and ease of use. Results demonstrate that our design produces clean and consistent notches while lowering both manufacturing costs and maintenance demands. The final design provides CLN of South Florida with a reliable, cost-effective tool that improves production efficiency without sacrificing performance.
