Final: Fabrication

Friendly Fabrication Partner Form
Friendly Fabrication Critique Form
End of the Year Survey

Deadline: 6/8/15

Introduction

Interpreting dimensioned drawings is an important engineering skill. Using drawings to create a computer model of a part or product is also important. Communicating information effectively allows a group of people to function as a design team.

In this project you will further develop your modeling skills and your ability to use a computer as an efficient communication tool. The skills that you learned earlier in this course will be systematically applied to model and fabricate a 3D object.

Concepts

• Researching the pros and cons of 3D printing
• Understanding that technical drawings convey information according to an established set of drawing practices which allow for detailed and universal interpretation of the drawing
• Advanced modeling features, as a way of creating three-dimensional solid models of complex parts and assemblies within CAD, using appropriate geometric and dimensional constraints
• Collaboration with fabricators

Procedure

• Research:

How long will it take to have your part printed? What will it cost? Where will it be coming from? What specifications will you need to share with them? Research the 3D printing process. Determine which facility/fabricator will best serve your needs -- specifically, the size and weight specifications that meet expected cost.

• Sketch:

What part would you like to see fabricated? What constraints will you need to work within? Create multiview sketches of your part in your engineering notebook.

• CAD:

How will you transform your 2D sketch into a 3D model? Model your sketches in Inventor.

• Fabricate:

Share your .STL files with a fabricator, and document your fabricated object.

Deliverables

• Research notes on the pros and cons of 3D printing
• Multiview sketches of your object
• Assembly file of your parts
• .STL file of your object
• Fabricated object made by someone else

Conclusion

Complete a reflection for the following topics as they relate to your own work. Provide facts and evidence to support your opinions.

• What do you think of when you see something that comes from a machine? How is it different when it’s made by a human?
• Are working drawings always necessary in order to communicate the design of a consumer product? Justify your answer.
• Animated assemblies are not typically included as part of the technical documentation of a design. How can 3D animated assembly models of an object or a proposed design be used in the design process? Beyond the design process?

Maker Faire Reflection Post

Designing and building a game from scratch is a challenging process, even more so when working with a big team and on a short timeline. The beta test of Adrastus at Maker Faire was very well received! Take some time to review the survey responses (via the WHS Intro to Design Drive account), and discuss next steps. Specifically:

• How did the Maker Faire Design Showcase meet your expectations? What do you feel was successful about our showcase? What would you plan to do differently next time?
• Did you find any of the other showcases at Maker Faire to be inspirational?
• What did you notice to be the overwhelming response from those that filled out the survey?
• Knowing what we know now from the beta test, what would you like to see happen next in this game design process?
• Be sure to include documentation you took at Maker Faire.

Dimensioning Standards

The basic standard dimensioning method established by the American National Standards Institute and the American Society of Mechanical Engineers (ANSI or ASME) is used to apply measurements to parts to enable clear communication. In order to communicate effectively, a person needs to understand the rules of the language and to follow the standards set down so that anyone who reads the dimensioned drawing will understand the intent and then be able to manufacture the part correctly.

Continue your practice of dimensioning by applying the appropriate dimensions and learning to understand the thought process that is used to create a clear and concise message regarding the size and shape of an object or product.

Deliverables:

1. Post all 3 drawings of the dimensioned parts you created.
2. Write a reflection on your process addressing these points:

• What is the difference between size dimensioning and location dimensions?
• What is the difference between chain dimensioning and datum dimensioning? Which method generally results in smaller dimensional deviation in manufactured parts?
• What are the similarities and differences between communicating about an object or product part through a dimensioned drawing and through a written description?

Additional Resources:

Dimensioning Standards Power Point

Maker Faire Game Research

We'll need to work as a team to design our showcase concept Maker Faire, but first brainstorm on your own to determine the types of games you're inspired by. Pick one game to research more deeply, and write a post outlining these points:

• What is the game like?
• How was it developed?
• Who developed it?
• Why was it created?
• Was is this game intriguing to you?
• Include documentation of the game (photos/videos)

To fill out the Interviewing an Engineer survey, please click here.

Reverse Engineering

What is it about an object that captures a person’s attention? Its function—the speed, efficiency, reliability?  Its form— the color, shape, proportion? With an understanding of form follows function, and some insight into the visual design principles and elements, you will be able to create products that capture the attention and imagination of the viewer. 

This week, working in a team of two or three, you will act as an engineering team for a novelty toy company. Your company has noticed the skyrocketing sales of the Automoblox vehicles and would like to design accessories or enhancements that can be purchased separately but will work with the existing toys. As a first step, your team has been assigned the task of reverse engineering one of the Automoblox vehicles. This will follow a process of visual analysis, functional analysis, and structural analysis.

Deliverables

Monday, 2/23:

• Intro to Reverse Engineering + Maker Faire prep

Tuesday, 2/24:

• Visual analysis of Automoblox

Wednesday, 2/25:

• Functional analysis of Automoblox

Thursday, 2/26:

• Structural analysis of Automoblox

• Reverse Engineering Reflection Post

Friday, 2/27:

• Instant Challenge

Reflection Post

How do visual design principles and elements impact the commercial appeal of a product?

What does a black box represent in the system input/output model?

Why do engineers perform reverse engineering on products, and how would you describe it in your own words?

Part of the mission of Automoblox is to "offer a high quality building system that will delight and inspire children while fostering the development of important skills and learning foundations." If given the opportunity, how would you improve the Automoblox design (visually, functionally, or structurally) while furthering the mission of the company at minimal cost?

Geometry of Design

A CAD model can quickly display an engineer’s ideas in a realistic way. And once an engineer has developed a model in CAD representing an idea, the idea can be shared much more easily with a wider audience. As is the case with technical sketching, CAD models must begin as sketches of points, lines, and shapes. However, a computer model can be much more accurate and precise than a freehand sketch. The lines of a CAD sketch can be drawn perfectly straight (or perfectly circular), with start and end points that occur in exact locations in space. A line may also be given precise length through the use of dimensions. If more than one line is being sketched, they can be made perfectly parallel or perpendicular or shown at a precise angle. CAD programs give designers the ability to sketch any kind of geometry and provide the ability to dimension, extend, rotate, mirror, copy and paste, pattern, move, and trim (to name a few tools) that geometry. Whereas hand-drawn representations are made to appear three dimensional by the strategic placement of additional points, lines, and shapes, CAD sketches can be transformed into 3D models using features that appear to add and manipulate material. As a result, within the software designers can extrude, revolve, or sweep a sketch such that the two dimensional sketch appears to become a solid form that can be electronically manipulated and viewed from any angle. Once a 3D model is created, the solid form can be hollowed out or the edges can be rounded.  

Deliverables

Tuesday, 2/17:

• Intro to Geometry in CAD + Brainstorming Maker Faire

Wednesday, 2/18:

• CAD Model Features 

Thursday, 2/12:

• CAD Model Features

Friday, 2/13:

• Instant Challenge

Reflection Post

What are the various geometric shapes and how are they defined by their characteristics?

How are physical properties of objects used to define design requirements?

What advantages do CAD programs provide over traditional paper and pencil design? What advantages does paper and pencil design provide over CAD?

Geometric Constraints

Trampoline by Joshua Jenkins

Geometric shapes are found everywhere. Take a moment to analyze products or objects you use every day. Geometric shapes and solids are the basis of these products. Engineers who have a strong understanding of these shapes, solids, and other geometric relationships can help designers develop and create solutions to a variety of problems. As designers progress through the design process and these design solutions are formalized, the level of accuracy and precision in the design specifications must increase. Conceptual sketches are converted to computer models and formal drawings, which include annotations describing the size and characteristics of the design features. A strong understanding of shapes and other geometric relationships is necessary to effectively and efficiently develop these computer and graphic representations.

Deliverables

Monday, 2/9:

• Discuss geometric constraints
• Calculating Properties of Shapes

Tuesday, 2/10:

• Inventor Research

Wednesday, 2/11:

• Review Calculating Properties of Shapes

Thursday, 2/12:

• Teach What You Know: Understanding Inventor

Friday, 2/13:

• Instant Challenge

Reflection Post

1. What shapes did you use in the design of your model shelter, and why did you choose those shapes?

2. What angles resulted from the shapes you chose?

3. What was the overall surface area of the shelter’s exterior? What material would you cover the outside of your shelter with, and how much of it would you need?

4. What was the overall surface area of the shelter’s interior? Approximately, how many people would comfortably fit in your shelter?

5. What external load factors did you taken into account for your shelter? How did you design your shelter model to meet those constraints?

6. How did you consider “form follows function” in the design of your shelter?