CS 294-10: RAPID PROTOTYPING
Lecture #1 -- Aug. 29, 2003.
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What Is CS 294-10 All About ?
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CS 294-10 in the curriculum
A nice complement to CS284: "From virtuality to physicality"
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What you will learn
Rapid Model Making tecniques
-- primarily use of FDM and 3D printing through hands-on experience.
For context, we will also talk about:
Other Layered Manufacturing Techniques;
Rapid prototyping techniques using NC milling;
Making a pilot batch of parts by injection molding;
Languages to describe parts for submission for fabrication.
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Teaching style, grading policy
This is a seminar-style course: Class participation is important.
This is a hands-on course: Every student will design and build one
or more parts.
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Course organization
Q&A -- pending issues ?
Characteristics of Rapid Prototyping
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Rapid turn-around time
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Little process planning
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Build one item at a time
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Additive methods versus subtractive methods
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Building versus machining
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"Amateur Fabrication"
See
intro slides of our course (organized by Prof. Sara McMains) at SIGGRAPH
2003
REVIEW SUMMARIES:
Rapid Prototyping by Solid Free-form Fabrication
(Additive Methods)
On-line course
notes by M.Bailey from Siggraph'96.
Rapid
Prototyping of Solid Three-Dimensional Parts" Technical Report by Sara
McMains
Rapid Prototyping by Machining
In Numerically Controlled (NC) Machining material is removed by a cutting
operation:
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Turning
- - Piece turns on a lathe, cutting tool is stationary.
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Drilling
- - Piece is fixed, rotating tool drills cylindrical holes.
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Milling
- - Piece is fixed, rotating tool removes pockets of material.
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CyberCut
= 3-axis milling + Reference-Free Part Encapsulation (RFPE)
- - Piece is encapsulated in plastic, which gets replaced after all
operations for one access direction have been done.
Producing a Pilot Series
A Successful Prototype may be followed by a series of many parts for product
trial:
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Casting
- - make a master (e.g., wood -- wax);
- - take a negative mold (e.g., sand -- plaster);
- - cast many copies (e.g., cast iron -- bronze);
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Injection Molding
- - directly machine the mold (e.g., aluminum);
- - form parts by injecting hot plastic (reuse mold).
First Homework Assignment:
A#1: Explore the Spectrum of Manufacturing Methods
To put the Layered Manufacturing Methods, which are the focus of
this class, into proper perspective,
Use the Manufacturing
Advisory Service
to find out what methods may exist to make some contiguous part
of uniform material composition.
Pick 3 different parts that are contiguous solids of one and the
same material
(e.g., plastic cup, steel spoon, bronze book end, church bell, car
suspension spring, wooden salad bowl ... )
and using the "MAS", find out what options for manufacturing this
web page recommends,
assuming that you want to make just a few prototypes.
-- Write / print out a little summary of your findings for
each of the three parts studied.
-- Note, whether and when any Layered Manufacturing Techniques are
recommended.
-- Make suggestions, how this MAS could be made more useful or easier
to use.
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