This design report provides an overview of the design process used by the U of M Team to develop a 2-dimensionl adjustable mold for Structural Composite Technologies’(SCT)custom transformer pad (T-Pad) production process. The purpose of designing the adjustable mold was to reduce the high production costs and long lead times for the current custom T-Pads. Additionally, the adjustable mold was intended to improve the surface quality of the custom T-Pads. Deliverables for the project include a SolidWorks model of the final design, engineering drawings, operation instructions, formal quotes, a Bill of Materials (BOM), and a design report detailing how the mold meets the project metrics. The adjustable mold needed to meet several target metrics that were composed by SCT and the U of M team at the onset of the project. Key metrics included the mold size which needed to range from 5’ x 5’ up to a size of 10’ x 8’ and have a height of 36”. Height adjustability was an optional component of the design scope. Additionally, the mold needed to be discretely adjusted in increments of at minimum 6” in both directions. The other key metrics were assembly time and mold maintenance which needed to be limited to two hours for two people and 15 minutes per mold cycle respectively. The mold required a maximum weight of less than 3750 lbm such that it could be transported by forklift intact if required and a maximum individual component weight of 100 lbm to meet the requirement of two workers being able to assemble the mold. Finally, after a detailed economic analysis based on previous custom T-Pad sales volume, it was determined the capital cost of the mold needed to remain under CAD$ 25,000 but would be competitively advantageous if it remained under CAD$ 10,000. A female mold design was preferred over a male mold design to improve the surface finish of the finished T-Pads. Based on these core metrics the U of M team developed a preliminary list of 62 component-based concepts. These components were then combined into preliminary list of 15 complete concepts. These 15 concepts...