Student Case Study: Windshield Wiper Bracket Repair
- jonathang22
- May 14
- 2 min read
Updated: May 28
By Matt: Selkirk College Student of the Digital Fabrication a Design program.
Challenge:
While taking the windshield wiper blades off at the end of winter, part of the plastic tab broke off leaving
the part and wiper blade inoperable. Through a winter of extreme cold weather and snow , combined with washer fluid and UV rays the plastic became brittle. The part broke from the stress of removing it. This part is the cover for the main anchor and pivot point between the “wiper arm” and “wiper blade.” With this broken there is no structural integrity holing the two parts together.
Options for Solutions:
In the past there were limited options to solve this problem.
1. The first option would be to glue the parts back together.
Pros - Quick, Simple and Cheap
Cons - Broken tab might be lost.
Unlikely to hold up against the wear and tear
2. Buy a replacement part.
Pros - The replacement part would be brand new and a direct replacement
Cons - Ordering a new part involves buying the whole wiper blade. This is roughly a
$70 item and is excessive and wasteful considering such a small part is needed.
- The new part is just as likely to break in the same spot again in the future. Solution or recommendation:
The solution to fix this problem was to scan the broken object and edit the part to restore it to it original
design. In doing this it is also possible to reinforce the part in the areas that it is showing weakness. This was done by adding some extra material and changing the shape slightly to reduce stress concentration point. With the file complete traditional FDM was used. Fine details and the complexity of the part did not allow for this to be a high quality option. The high print quality and detail of the Nylon MJF method made it the perfect candidate for this object.
There were several steps involved in implementing this solution:
• Scan the broken object.
• The scanned model was edited using VX Elements. This software allowed me to clean up the broken area and mirror the good side. Creating a new symmetrical object.
• The model was then cleaned up and smoothed out to remove any imperfections. Critical areas were reinforced to make them more robust. Some of the other contact areas were cleaned to make sure the new part fit true to the original.
• Once the model was completed the file was sent to the HP Nylon MJF printer and a new part was made.
The biggest challenge was getting the tight tolerances of the contact point to fit. The part does fit and do it’s intended job but there are a few little areas that could be modified slightly to help the part fit perfectly. The repair of the windshield wiper bracket was a success! The test now will be to see how the material will hold up to the Snow, UV and washer fluid of a winter season.
