Modeling & Manufacturing Using Alpha_1 Samuel Drake

1984 -- Start of what became the AML Purchased 5-Axis Vertical Machining Center First Manufactured Item – 3D surface for a shaped charge Second Demonstration Item – Injection mold for a teaspoon that had been modeled by Beth Cobb. Made Plastic spoons with an Alpha_1 logo

Adding Capability to the AML 1989 Mill-Turn 1991 Stereo Lithography Rapid Prototyping 1992 Sinking EDM 1994 5-Axis Horizontal Machining Center 1995 Wire EDM ?? Coordinate Measuring Machine 2002 Move to High Bay in Kennecott 2005 High Speed 5-Axis Machining Center

Moving into Kennecott

Major Machine Lineup in AML

Parts on Demand System and Bushing Maker ~1989 Started working with Hill AFB Origins of what became FeatureCAM Developed Bushing Maker Software with EGS Live Demo in AML Demo with EGS at Hill AFB

Early Work on FeatureCAM Prior work with Samuel Sela on defining features for feature-based design Basic concepts for FeatureCAM came from talking with Russ Fish on how to automate “Parts on Demand System” Concepts of using stock and part is what is left after subtracting manufacturing features. Work with Chi Cheng Ho and Beth Cobb on making manufacturing features.

Modeling and Manufacturing Air Force Parts -- F4 Sway Brace None of the Air Force drawings were technically correct

1993 Modeling and Manufacturing First Complex Assembly Front Upright, Spindle, Hub, Caliper, Brake Rotor for Mini-Baja Went together with no rework, forever proving the value of manufacturing from solid models

Early 90’s--Work with DARPA on Modeling and Manufacturing Diesel Engine Major modeling effort with many of the Alpha_1 staff involved in modeling different parts. Made animated video of running engine Made 1/3 scale model using Stereo Lithography Rapid Prototyping Machined 1/3 scale model from Aluminum Part way thru, DARPA wanted it to actually run. Made it run on compressed air

Collaborative Work with DARPA ~ 1995 – Early use of web-based collaboration with Stanford and others (Michigan State?, Cornell?) to design and build electro-optical tracker

Collaborative Work with UNC and Henry Fuchs Optical Sensor Ball Multiple Camera System for Video Conferencing Plastic Mold for Stereo video/optical head mount display for surgery Multi angle mirror device

1996 -- More Complex Modeling and Manufacturing Final Drive for Formula SAE First Use of Wire EDM to cut splines and gears

More Gear and Splines

FormulaSAE Intake Manifold Made wax cores using FDM Rapid Prototyping Machine. Cores wrapped with composite. Wax melted after composite was cured

Manufacturing a FormulaSAE Car using Alpha_1 and FeatureCAM Alpha_1/FeatureCAM Parts Composite Chassis Wheel Centers Front and Rear Suspension with integrated brakes Final Drive with quick change Gears Intake Manifold Gear Shifter Throttle Body 2006 Car with the Team Captain

Drilling for Oil Diamond Drill for high speed drilling Modeled from “napkin sketches plus cutter locations New Design with rotating cutters

Multi-Mode Microwave Antenna for L3 Comm Replaced 44 parts with 3 parts by realizing the desired shape was a ruled surface that could be cut with a 4-axis wire EDM

Full Scale Diesel Engine Parts

Current Work using FeatureCAM