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

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

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

4. 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

5. 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

6. 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

7. 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

8. 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

9. 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

10. How it Works Objet Overview http://www.youtube.com/watch?v=sNyIOPrXhd8
-MUTE SOUND & DON’T SHOW ENTIRE VIDEOS (unless time permits)
3D printers (cubiify.com) readily available for $ $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

11. 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

12. 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

13. 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)

14. 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.

15. Functional Prototypes
Test function before mass-production

16. Considerations Tolerances Build Sizes Material Properties
+/ inch or +/ 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

17. Companies Machine Providers On Demand Service Providers
Stratasys =
3D Systems =
Cubify =
Objet =
On Demand Service Providers
Quickpart =
Proto Labs =
RedEye =
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

18. Case Study Examples Tape Wrangler Case Study Oreck Case Study
Oreck Case Study
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.

19. 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

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

21. 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

22. 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?

23. 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.

24. 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.

25. 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.

26. 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.

27. 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.

28. 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

29. 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.

30. 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.

31. 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

32. 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

33. 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.

34. Break
5 Minute Class Break

35. Live Instructor Demo
Live Instructor Autodesk Inventor Demo

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

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

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

39. Assignment Plastic Part Design Essentials 2011Course
Plastic Part Design Basics Unit

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

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

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

43. 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: ]

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

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

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

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

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

49. 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

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

51. 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.