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Design Realization lecture 9

Design Realization lecture 9. John Canny 9/23/03. Last Time. More on kinematics and IK. Some concepts from dynamics. This time: Manufacturing & Materials. Manufacturing is undergoing a revolution: Traditional methods: Casting, molding, fusing, slumping

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Design Realization lecture 9

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  1. Design Realization lecture 9 John Canny 9/23/03

  2. Last Time • More on kinematics and IK. • Some concepts from dynamics.

  3. This time: Manufacturing & Materials • Manufacturing is undergoing a revolution: • Traditional methods: • Casting, molding, fusing, slumping • Milling, lathing (non CNC-versions) • Stamping • Rolling, extrusion • Shape is “write-once” (not programmable) in these methods.

  4. Next-wave Manufacturing • Reprogramming shape: • CNC machining: A computer outputs a path for a cutting tool to create a specified surface. • Not new, but now inexpensive, PC-based. • Plastics, wood, metal, glass. Flashcut 2000, XYZ-axes, 9x7x6.5”, $2895

  5. Milling • Milling involves a moving XYZ head that cuts into the workpiece: • Bits can achieve differentfinishes.

  6. Lathing • Lathes cut circularly symmetric parts. • Shafts, furniture, fasteners,… lenses. • Can also do grinding and polishing.

  7. Milling Example • CNC milling example (Deskproto web site) • Finish is quite smooth • ballnose cutting tool. • Lots of waste, but can be recycled!

  8. Next-wave Manufacturing • PC-boards: • Created with CAD tools. • Photographic reproduction: • Low cost in volume. • High complexity possible. • Multi-step process, BUT: • Web-based services have 24-hour turnaround, low cost.

  9. Next-wave Manufacturing • CNC Laser cutter: • X-Y axes control a powerful laser. • Fine line (0.007” or better). • Positioning to 1000 dpi, • Some control of depth: • Engraving as well as cutting. • Moderate cost:$10,000 Versalaser 16x12” workspace.

  10. Laser Cutter Capabilities • Precision is good enough to make smooth sliding surfaces (gears). • Layering can be used to make3D surfaces (very popular for architectural models). • Can even make PCBsby etching metalfrom clear plastic!

  11. Other 2D Cutting Technologies • Lasers can cut metal, but not easily • Power limits, need to deal with material removal. • Plasma cutters use an electrically-generated plasma jet to cut • Sweeps away material.

  12. Plasma Cutters • Thin shapes in a variety of metals. • Torchmate 3 machine is $10,000 for 4x8’workspace.

  13. Water Cutters • Similar idea to plasma but based on high-pressure waterjet. • Cleaner method: water plus metal can be collected. • Cost??

  14. 3D printers • A variety of 3D printing techniques have appeared in the last few years. • SLA: Stereolithography: laser curing of liquid plastic. • SLS: Selective Laser Sintering: similar, laser fuses powder. • LOM: Layered Object Modeling: laser cuts paper one layer at a time. • FDM: Fused Deposition Modeling: a thread of plastic is melted through a moving head.

  15. Stereolithography: SLA • Earliest 3D method, based on UV-set polymers. • Resolution quite good: 0.002” layers. • Curing needed before part can be used.

  16. LOM: Laminated Object Modelling

  17. FDM: Fused Deposition Modelling • FDM is one of the most versatile 3D methods • Many materials can be used:solvent-based or thermo-plastics. • Requires X-Y-X motion (like a CNC machine). • Stratasys machines start at $30,000

  18. Roll-your-own 3D Printers • Material feeding heads are commercial modules. • Microfab makes heads for solvent-based and thermo-plastics. • Add a CNC XYZ-stage to create your own printer.

  19. Roll-your-own 3D Printers • Polymer electronics is printable with microfab heads, working on actuators. • Potential for printing complete electro-mechanical systems. • Two prototype printersat Berkeley.

  20. 3D Printer Disadvantages • Slow! Adding material is much slower than removing it. • Speed scales very poorly with resolution: double resolution and decrease speed by 8x. • Laser 3D methods faster (than other heads) for equivalent resolution, but limited materials.

  21. 3D Printing Data • The standard 3D printing format is “STL”. • Available as an output option for most CAD tools, as a 3rd-party translator for Maya. • Then process-specific CAM software (Computer-Aided Manufacturing) creates a tool control file: • Tool path for milling and lathing. • Slices and support structures for 3D printers.

  22. Summary • CNC machines provide shape programmability. • Lathes and mills provide traditional shaping. • Layered methods can create almost unlimited shapes, but slowly. • 2D and 3D shaping methods generally based on CNC motion of an active head. • Architecture of shaping machines is open: movement and heads are available separately.

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