Project 3: Fab-You-Lous Design James Winton- AMPD- 17 March 2017

Project 3 scope

The Scope of project 3 is to design, create, and produce three separate products from the three different machines available in the CART lab: the 3D printer, the laser cutter, and the CNC wood mill. This project is to learn the limitations and overview of design for manufacturing with the process from drawings all the way to the final product.

DFM

Abbreviation of Design For Manufacturing, this encompasses all the important factors of engineering when creating a new part, material, building, or assembly and critically thinking about the possible errors, setbacks, limitations, and issues that can arise when bringing your idea from a draft to a physical product (Anderson 2017).

Different Manufacturing Processes Used

Additive

Additive manufacturing is a process that adds material to create a 3-dimensional object (Paramasivam 2016). For example, we used FormLabs Form2 SLA 3D printer for project 3 to create a 3-dimensional object that we had previously created in SolidWorks. The machines takes a plastic, melts it, then spits it out of a nozzle on the print bed and as it cools it becomes 3-dimensional to be layered over again and again therefore being so built from the ground up.

MakerBot Replicator 2 3D Printer

Subtractive

Subtractive manufacturing is a process nearly opposite to additive, as it cuts away material in the shape of the designers choice (Paramasivam 2016). In project 3 we used the SRM-20 wood CNC mill to take a block of wood and “subtract” material from the original block until it is cut down into the desired design.

Wood CNC Mill

Cutting

This type of manufacturing is simple as it uses a method to simply cut material. This includes water jet cutters, saws, ect. and the Versa Laser laser cutter, which we used in project three. The laser cuts through the wood to cut out and make the desired design. This could similarly be compared to subtractive manufacturing as it removes material to create a desired design.

CO2 Laser Cutter

How DFM is Applied

3D Printing

The design for manufacturing applies to the additive section of manufacturing with the 3D printer we used because realistically not everything can be 3D printed. If a part has a section that is thinner than the nozzle head of the printer, it wont be able to be constructed, there is a thickness limitation. The FDM printer cannot print sections that are overhanging without a support layer because gravity will pull it down before it stiffens back up. There is a shape and design limitation as well. the printer prints in layers, so if an object has a curved surface it will not be perfectly smooth due to the way it prints from the ground up in layers.

Custom designed 3d printed surfboard

CNC Wood Mill

The design for manufacturing applies to subtractive manufacturing and the CNC mill we used because material is being removed from a drill bit that is a certain thickness along with being round which will limit how thin of a cut could be made and how sharp of a corner could be made, no thinner than the bit itself and no sharper than the roundness of the blade. Along with this design limitation, subtractive cannot produce overhanging parts as it removes material from the top down.

Laser Cutter

The design for manufacturing applies to the laser cutter because it uses a CO2 laser that burns through the wood, therefore if some cuts are too close together or too small, the material inbetween may be burnt off or burnt to a chard color and not come out as desired. There is a size and design constraint along with the limitation to 2 dimensions cutting on only the x and y axis do a thin depth of the slice of wood being used.

Original laser cut name piece

Anderson, David. “DESIGN FOR MANUFACTURABILITY.” Article on Design for Manufacturability. Accessed 21 Mar. 2017.

Staff, Creative Mechanisms. “Additive Manufacturing vs Subtractive Manufacturing.” Additive Manufacturing vs Subtractive Manufacturing. Accessed 21 Mar. 2017.

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