Project 3 Products By Ajay Davis

The products I designed were a cup for 3D printing, a pedestal for production on the SRM-20, and a labeled plate for laser cutting. I designed each product with the intent of conforming to the constraints of each machine, and utilizing the practices of Design for Manufacturing (DFM). DFM is the concept of understanding the constraints of different forms of manufacturing, and integrating that understanding to make a product that is easier to manufacture efficiently. DFM is meant to turn Design and manufacturing planning into one seamless activity.

The 3D printer used in this project was the Makerbot Replicator. The Makerbot is a fused deposition modeling (FDM) printer, which is a method of additive manufacturing that deposits layers of plastic heated to an almost fluid state. The plastic quickly cools, which allows for subsequent layers to be built on top of it. Key factors to understand in the process of designing for 3D printing are overhangs and hollow spaces. If a large portion of the object "sticks out" from a base that has been already built earlier in the print process, support material will have to be used to ensure that the filament that makes up the overhang does not simply drop down from the extruder head.

The Makerbot Replicator used in Project 3

The cup was was printed using the spiral vase setting on the software “SliC3r.” Spiral vase prints strands of filament in a completely unbroken spiral. This means that there are quite a few constraints as to how the horizontal profile of an object can be shaped, and the fact that no support material can be used. The resulting print is completely hollow, as can be seen from the images in the embedded video.

The SRM-20 is a desktop router used for cutting wood and other soft materials. It utilizes a rotating spindle and three axes of movement controlled by stepper motors to move. The diameter of the spindle and the size of available stock pieces to cut from greatly affects the overall quality of the cut. Since the SRM is a machine that uses subtractive manufacturing, there is a lot of waste in the form of wood shavings that is produced during the course of a cut. In order to properly utilize DFM with this machine, one should never expect sharp inset corners from the perspective of a plane normal to the build plate due to the diameter of the spindle.

The part for the SRM-20 was designed entirely without any sharp inner corners on the horizontal plane. I designed the pedestal this way so that I wouldn't have to deal with fillet-like structures resulting from the diameter of the tooling used. The idea of DFM let me plan for this constraint, so I created a design that almost entirely utilizes large circles so as to eliminate any possibility for large unplanned structures.

The VersaLaser 4.60 is a laser cutting/engraving platform for wood and other soft, thin, materials. It Utilizes a CO2 laser and an adjustable focus to cut and engrave 2D designs onto the material.

The part for the laser cutter utilizes the precise nature of laser optics to engrave detailed markings on a small plate of wood. The laser cutter cannot fully create 3d designs by itself, so this constraint was accounted for in my design by instead focusing on a high resolution image.

Grieser, Franz. “FDM Vs. SLA.” All 3DP. All about 3D printing, October 8, 2015.

Hultgren, Kacie and Matt Stultz. “A Guide to Buying Your First Laser Cutter.” Makezine. Make: Magazine, December 2, 2015.

“Makerbot User Manual.” Makerbot. Makerbot inc.

“Srm-20 User’s Manual.” Support.RolandDGA. Roland Corp.

“User Guide.” VersaLaser. Universal laser systems

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