Week 3 - Lecture Detailed Component Design Justin Rice February 2, 2012

Week 2 Problem Set Ensure all week 2 problem set assignments are submitted. How long did it take?

Open Q&A Open Q&A about week 2 topics How many of you have engineering experience?

Quiz #1 – Week 1-3 Topics Quiz #1 during first 30 minutes of Tuesday’s lab sessions on topics from weeks 1-3. The content of the projects will be covered in the quiz

Lecture Topics Product Engineering Part 2 Rapid Prototyping Designing for Manufacturing Intro Designing Styled Components Designing Plastic Components Case Study Examples plastic and styled are designed differently than Steel parts

Product Lifecycle – Week 3 Portfolio Management Conceptual Design Product Engineering Requirements Manufacturing Engineering Simulation & Validation Build & Produce Confirm Students know where they are in the Product Lifecycle Disposal & Recycling Maintenance & Repair Sales & Distribution Test & Quality

3D Design Use CNC Manufacturing Rapid Prototyping Automation 3D CAD Model Design Detail and Form Visualization These are all of the downstream uses of the 3D model and benefits to leverage the digital asset. This Lecture focus on RAPID PROTOTYPING & DESIGN DETAIL and FORM Simulation / Analysis

3D Design Use CNC Manufacturing Rapid Prototyping Automation 3D CAD Model Design Detail and Form Visualization These are all of the downstream uses of the 3D model and benefits to leverage the digital asset. A lot of advancements in this area and appears to be on the verge of exploding Simulation / Analysis

Common Terms Rapid Prototyping Rapid Manufacturing 3D Printing General term for automatic construction of a physical prototype object on a machine. Rapid Manufacturing General term for the automatic construction of a physical object that will be used as a production item. 3D Printing Process for creating 3D objects from a materials printer. Generally more desktop and affordable machines. 3D printing is more desktop affordable machines. More general term Main stream a lot more accessible then ever before

How it Works Objet Overview http://www.youtube.com/watch?v=sNyIOPrXhd8 http://www.youtube.com/watch?v=CEA2HaFqsVQ http://www.youtube.com/watch?v=B9VOwqtOglg -MUTE SOUND & DON’T SHOW ENTIRE VIDEOS (unless time permits) 3D printers (cubiify.com) readily available for $2000 - $100k Big topic when talking about next generation manufacturing. Video 1: While the tan material settles, the white material supports it, then a waterjet removes the white material Video 2: Professor expanding the size of what can be printed. Fast Forward to 1:40 to show placing parts. Video 3: metal shapes can be fabricated that were nearly impossible before

STL Files Industry standard file format used by Stereolithography software to generate information needed to produce 3D models on rapid prototype machines. Higher resolution files with a smaller surface deviation. Most CAD can export STL format Allowable deviation controlled in export Mature process, defacto standard Direct measure of the quality of the part BE AWARE: Entire part is designed to 1 tolerance in 3D Printing

3D Printing Applications Concept Models Used to evaluate, optimize, and communicate your designs. Functional Prototypes Allow you to test in real-world environments and make decisions. End-use Parts Build small quantities of parts that are tough enough for production. Printing models halfway across the world for customers to inspect Accessibility to remote areas of the world, in space or under sea Spare parts made on demand

Benefits of Rapid Prototyping Time Savings Improve Design Increase Visualization Cost Savings / Reduction No prototype tooling and parts Small Qualities Detect design flaws early Shorten cycles Tooling cost eliminated 3D Print to anywhere (Antarctica, space station, or submarine). (no shipping cost)

Validate Design Form Able to wrap your hands around it to get a feel Eliminating prototypes and mold cost You can’t touch your 3D virtual design but you can hold a printed prototype. e.g. If you are designing a phone/steering wheel/game controller, you can test ergonomics.

Functional Prototypes Test function before mass-production

Considerations Tolerances Build Sizes Material Properties +/- 0.005 inch or +/- 0.0015 inch per inch whichever is greater Build Sizes 15” x 14” x 15” (Average) 36” x 24” x 36” (Large) Material Properties Wax Based Materials Plastic Based Materials (ABS, Polycarbonate) Metal Based Materials (Newer) TOLERANCES larger part larger tolerance everything is the same tolerance no way to identify critical areas If tighter tolerances are needed then overdesign and machine after printing SIZE sometimes you create half scale versions to visualize if needed to save money Printing building using a Mechanical arm to increase Build size MATERIALS Printing Organs Todays practices will be appear like the dark ages of manufacturing

Companies Machine Providers On Demand Service Providers Stratasys = www.stratasys.com 3D Systems = www.3dsystems.com Cubify = http://cubify.com Objet = www.objet.com On Demand Service Providers Quickpart = www.quickparts.com Proto Labs = www.protolabs.com RedEye = www.redeyeondemand.com Buy the Machine Market leaders Cubify allows anyone to design something and print it at home or pay for the Service on demand A lot of consolidation in the market Parts that are no longer available submit a model an online Service provider and receive the part in as little as 24 hours

Case Study Examples Tape Wrangler Case Study Oreck Case Study http://www.youtube.com/watch?v=M_F6KlbFK4M Oreck Case Study http://youtu.be/9ipyauy81sU Show videos, time permitting (students will need to hear the sound) TAPE WRANGLER Summary: Won a large contract because they redesigned and printed a new prototype in 30 days. Also saved a lot of cost on producing the prototype. ORECK Summary: Oreck use 3D Printing to save 60% on their fixture designs.

3D Design Use CNC Manufacturing Rapid Prototyping Automation 3D CAD Model Design Detail and Form Visualization These are all of the downstream uses of the 3D model and benefits to leverage the digital asset. Simulation / Analysis

Design Detail and Form Complex and Styled Parts Next we will discuss the many ways to design these complex parts

Plastic Part Modeling Methods Solid Shell Method Surface Thicken Method SOLID > SHELL We can build a solid and then shell the body. Wall thickness is very critical to how much time a plastic mold injection part needs to cure or material flows in the mold SURFACE > THICKEN It maybe easier to design a surface and then Thicken into a solid

Designing Styles Parts Industrial design products like Autodesk® Alias® support rapid creation and manipulation of complex surfaces and development of Class-A surfaces. LEFT IMAGE Many times a free form design tool such as Alias is used to model the Class-A side of a component. This is the side the customer looks at and hopefully entices them to buy. RIGHT IMAGE The engineers and manufacturers are more concerned with the inside of the part. Can I save cost by simplifying it? Will the snaps hold the wear out over time? Are the ribs strong enough?

Design for Manufacturing (DFM) What is DFM? DFM is the process of proactively designing products to optimize all the manufacturing functions to assure the best cost and quality. Why DFM? Lower development cost Shorter development time Faster manufacturing start to build Lower assembly and test cost Higher quality Products that are sold to the masses small cost cut have huge impact on savings SCENARIO: If you can lower the cost of manufacturing by $1 per Xbox then that translates into several million in profit. If you DFM then cost go down and quality goes up. There can be a trade off between Styling and Manufacturing Cost but that is not always the case.

Injection Molding Manufacturing The process consists of a mold that normally has two halves that seal together for the filling of melted plastic. Understanding how plastic part are made. Must design for part mold to come together and pull apart with minimal difficulty.

Injection Molding Machines When the mold separates the part should fall into a collection bin. Otherwise you add additional time and therefore cost to manufacturing.

Good Plastic Injected Part Design Most critical factor is keep the part wall thickness uniform throughout part. Have proper draft angle on part to ease ejection from mold. (0.5 – 2 Degrees Normal) Avoid undercuts requiring slider cores when possible to avoid complexity. Avoid sharp corners by adding radius. The ideal plastic part is a disc (such as a poker chip) because it has UNIFORM THICKNESS and no corners. larger DRAFT ANGLEs make it easier for the part to be ejected from the mold UNDERCUT require slider cores and adds complexity to the process SHARP CORNERS generate stresses in the material flow.

Examples Transitions must be designed UPPER IMAGES An immediate change in wall thickness will restrict material flow in the mold. Not shown: the transition on the right should have fillets for smooth flow. LOWER IMAGES Build the hole so it has a uniform thickness. Save on material cost. Add ribs to strengthen the hole if needed.

Mold Analysis Autodesk® Moldflow® allows you to simulate the filling of the injection molding process to predict the flow of melted plastic. Locate issues like short shots, weld lines, air traps, sink marks. Industry leading mold-flow simulation software

Moldflow Benefits Identify Possible Defects Optimize Manufacturing Weld Lines & Sink Marks Warpage & Shrinkage Optimize Manufacturing Ensure Proper Injection Mold Design Material Selection Simulation Use as-manufactured material properties Locate issues like short shots, weld lines, air traps, sink marks.

Summary Process Example Step 1 = Conceptual Design Step 2 = Product Engineering Step 3 = Produce Rapid Prototype Step 4 = Make Required Improvements Step 5 = Simulate and Test Design Step 6 = Visualize Design for Final Approval Step 7 = Manufacture for Production Production tooling is often a third party and not located in the same area (china) Modern processes and drastically be reduced Lifecycle time, remove cost and improve quality Surprising how many companies skip critical step, do not utilize current technologies, and waste time and money.

Franke - Case Study Challenge Results To maintain its competitive leadership position in the kitchen technology industry, Franke needed a continuous digital pipeline for its product design data. Results Enabled users to validate design and engineering decisions as they worked, minimizing the need for physical prototypes. Reduced costly engineering changes that previously were discovered after the design was sent to manufacturing. Helped provide quick and effective communication between diverse business teams. “Autodesk Inventor has played a critical role in helping us increase development cycle speed for new products. The ability to use digital prototyping to virtually explore a complete product before it is built saves us time at every step of the product development cycle, from the industrial design phase though the manufacturing process.” Christian Sperka Chief Information Officer Franke Switzerland

Jede Automater - Case Study Challenge To stay ahead of increasingly tough competition in the marketplace, Jede Automater sought an efficient development workflow with the Autodesk solution for Digital Prototyping. Results Designed, visualized, and simulated its products in Inventor to significantly reduce time to market. Reused design data and automated the release and change management processes using Vault Manufacturing. Collected direct feedback from customers with highly realistic renderings. “By virtually exploring our products before they become real, we are able to order materials at an early stage and easily stay within our budgets. It is quite clear that Digital Prototyping saves us both time and money.” Marcus Berntson Development Manager Jede Automater Sweden

Open Q&A Open Q&A time for discussion on topics Any experience designing plastic parts? Potential Q1: Why is rapid prototyping limited to the sizes on a previous slide? 15” x 14” x 15” (Average) OR 36” x 24” x 36” (Large) Potential A1: Those machines are available today (7/27/2012). As the market expands there will be more sizes/methods available.

Break 5 Minute Class Break

Live Instructor Demo Live Instructor Autodesk Inventor Demo

Guided Lab Project 1 Guides instructions for creation various fillet feature types.

Guided Lab Project 2 Guided instructions for modeling plastic component case.

Guided Lab Project 3 Guided instructions for modeling plastic component case.

Assignment Plastic Part Design Essentials 2011Course Plastic Part Design Basics Unit www.myigetit.com

Problem Set Assignment Model detailed plastic molded part with various features.

The following slides are used for key topics for live demo. Demo Topics The following slides are used for key topics for live demo.

Creating Draft Features Draft Ribbon: Model tab | Modify panel | Draft Keyboard Shortcut: D Draft Mini-Toolbar Options

Work Features Work Point Ribbon: Model tab | Work Feature| Point Keyboard Shortcut: . Work Axis Ribbon: Model tab | Work Feature| Axis Keyboard Shortcut: / Work Plane Ribbon: Model tab | Work Feature| Plane Keyboard Shortcut: ]

Creating Rest Features Rest Ribbon: Model tab | Plastic Part | Rest

Creating Grill Features Grill Ribbon: Model tab | Plastic Part | Grill

Creating Boss Features Boss Ribbon: Model tab | Plastic Part | Boss

Creating Lip Features Lip Ribbon: Model tab | Plastic Part | Lip

Creating Snap Fit Features Snap Fit Ribbon: Model tab | Plastic Part |Snap Fit

Creating Fillet Features Revolve Ribbon: Model tab | Modify| Fillet Keyboard Shortcut: F Extrude Mini-Toolbar Options OK Apply Cancel Selected Radius Value Fillet Style Options

Creating Rib Features Rib Ribbon: Model tab | Plastic Part | Rest

Solid Body Modeling Multi-body parts are a versatile and powerful approach to skeletal modeling. The versatility and power of multi-body parts is expanded with the ability to derive multiple bodies into a single part, conduct Boolean operations between solid bodies, split a solid body into two bodies, and move bodies within the part.