1. Modeling & Manufacturing Using Alpha_1
Samuel Drake

2. 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

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

4. Moving into Kennecott

5. Major Machine Lineup in AML

6. 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

7. 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.

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

9. 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

10. 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

11. 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

12. 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

13. 1996 -- More Complex Modeling and Manufacturing
Final Drive for Formula SAE
First Use of Wire EDM to cut splines and gears

14. More Gear and Splines

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

16. 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

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

18. 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

19. Full Scale Diesel Engine Parts

20. Current Work using FeatureCAM