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Effective: Summer 2014
ENGR 62C3-D PRINTING: ADVANCED MODEL MAKING5 Unit(s)

Prerequisites: Prerequisite: ENGR 62B.
Grade Type: Letter Grade, the student may select Pass/No Pass
Not Repeatable.
FHGE: Non-GE Transferable: CSU
4 hours lecture, 3 hours laboratory. (84 hours total per quarter)

Student Learning Outcomes -
  • Effectively create and analyze models and select proper materials and equipment for production.
  • Demonstrate proficiency with a variety of 2D & 3D modeling equipment using clay, plastic resins, and metal casting.
Description -
Focus on more advanced and complex methods used throughout the model-making industry. Students will develop skills in using computer-aided design and manufacturing equipment and software to fabricate models. Designs will be created on three-dimensional solid modeling software and transferred to a three-dimensional computer aided manufacturing software for coding and post processing. Students will fabricate parts on a variety of equipment which may include CNC mills and lathes, laser cutters, and two and three-dimensional rapid modeling equipment.

Course Objectives -
The student will be able to:
  1. Construct patterns and vacuum form/thermoform parts from a variety of plastic sheet parts.
  2. Build clay and plaster modeling using more refined techniques and adhere to precise tolerances.
  3. Construct patterns and parts from programmable 2D engraving and routing machines.
  4. Generate parts utilizing rigid, flexible, elastomeric and solid polyurethane resins.
  5. Cast metal parts using RTV molds and low melt metal materials.
  6. Analyze the model to be created and select proper modeling materials for each application.
  7. Create models utilizing a variety of 2D and 3D rapid modeling equipment.
Special Facilities and/or Equipment -
  1. Computers loaded with appropriate CAD and modeling software.
  2. Rapid Prototyping Equipment, which may include: CNC mill, Stereolithography Machine, Fused Deposition Machine, Laser cutting equipment.

Course Content (Body of knowledge) -
  1. Project Development
    1. Vacuum forming
    2. Reinforced plastics techniques
  2. Part Development
    1. Rigid tooling
    2. Flexible tooling
    3. Solid polyurethane casting materials
    4. Elastomeric polyurethane materials
    5. Rigid and flexible polyurethane foam materials
    6. Clay and plaster modeling
    7. RTV molds and low melt casting materials
  3. Surface Treatment
    1. Painting
    2. Plating
    3. Texturing
  4. Introduction to Computer-Aided Manufacturing Software.
    1. Cartesian coordinate system.
    2. Basic 2D geometry
    3. Project development with 2D cutting.
  5. CAD to CAM Integration.
    1. File transfer CAD to CAM
    2. 3D Surface Generation
    3. Setup and operation of CNC machines.
  6. 2D and 3D Rapid Modeling Equipment.
    1. Fused deposition model maker.
    2. Stereolithography
    3. Sintering systems
Methods of Evaluation -
  1. Quizzes and tests objective, essay, and performance - that measure student's ability to develop complex forms and shapes using a variety of more advanced model making materials and identify, explain, and fabricate advanced three dimensional models and prototypes using advanced techniques, equipment and various software.
  2. Laboratory assignments that require students to interpret and analyze industrial methods and procedures for producing advanced forms and shapes and select and apply CAD-CAM modeling techniques and equipment.
  3. Instructor assessment of in-class demonstrations/presentations that include an explanation of fabricating models using CAD-CAM equipment and software.
Representative Text(s) -
Lipson, Hod; Kurman, M., Fabricated: The New World of 3D Printing, 1st Ed, Wiley, 2013.
Barnatt, C., 3D Printing: The Next Industrial Revolution, CreateSpace Independent Publishing Platform, 2013.
Horenstein, Mark N., Design Concepts for Engineers, 4th ed, Pearson Higher Education, 2010.
Griffin, M. Design and Modeling for 3D Printing, Maker Media, Inc. 2014.

Disciplines -
Engineering
 
Method of Instruction -
Lecture, group laboratory projects.
 
Lab Content -
  1. Using a dimensioned drawing, cut the sides of boxes using a variety of materials.
  2. Bond a variety of materials to create boxes for silicone tooling.
  3. Using automotive styling clay, create a sweep with templates.
  4. Create a rigid plaster tool from the clay sweep.
  5. Create a rigid plaster casting from rigid plaster tooling.
  6. Create a flexible tool from a plaster sweep.
  7. Create a plaster casting from a flexible tool.
  8. Using a laser, cut acrylic into a variety of shapes
  9. Using high density foam, generate a foam model using templates.
  10. Create simple geometric shapes in a variety of drawing programs.
  11. Demonstrate image control in a variety of drawing programs.
  12. Set up and transfer images for engraving with a laser.
  13. Create a folding box with CAD software and prepare for transfer to the laser for cutting.
  14. Create a 3D sign and prepare it for the CNC mill for cutting.
  15. Create a 3D model and prepare it for the stereolithography machine, exploring the advantages of rapid prototyping equipment and the basic mechanical operation of a fused deposition machine.
 
Types and/or Examples of Required Reading, Writing and Outside of Class Assignments -
  1. Reading: Weekly reading assignments in college level texts and/or study guides and instructor handouts that enhance and enlarge upon lecture topics.
  2. Writing: Comparisons of samples of three-dimensional idealational illustrations using various techniques.
  3. Other:
    1. Create three-dimensional sketches using proper line conventions and visual communication techniques.
    2. Interpret and use industrial specifications and standards while completing laboratory case studies requiring selection and application of techniques and equipment.
  4. Oral: Class discussions and laboratory case studies in which student's explain experiences in the use of various techniques and elaborate on the merits of each.