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Effective: Summer 2014
ENGR 62D3-D RAPID MODEL MAKING & PROTOTYPE DEVELOPMENT5 Unit(s)

Prerequisites: Prerequisite: ENGR 62C.
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 -
  • Demonstrate proficiency in programming, setting-up, and operating a variety of 3D modeling machines to create complex parts.
  • Create and analyze computer generated models using advanced skills, techniques, and materials to produce high-quality parts.
  • Perform comprehensive design solutions presentations.
Description -
In this project development course students focus upon fabrication of a variety of complex models using advanced model-making equipment and rapid prototyping. Students program, set-up, and operate 3D modeling machines. Field trips may be required.

Course Objectives -
The student will be able to:
  1. Generate three-dimensional computer-aided parts including programming and setup of multi-axis CNC mills for part fabrication.
  2. Laser cut a variety of plastic, wood, and metal parts using multilayer material technology to produce three-dimensional parts.
  3. Set up and form a part on fused deposition and stereolithography modeling equipment.
  4. Relate through research other 3D modeling technologies that are emerging within the model making industry.
  5. Perform comprehensive design solution presentations.
  6. Create computer generated models using advanced skills, techniques and materials.
  7. Analyze computer forms and develop clean files for machining high quality parts.
  8. Demonstrate proficiency in programming, setting-up, and operating a variety of 3D modeling machines to create complex parts including a kinematic part assembly.
  9. Use quality control with various techniques in correcting computer-modeling errors.
Special Facilities and/or Equipment -
  1. Classroom equipped with computers and appropriate modeling software.
  2. 3D Modeling machines, CNC mill, fused deposition, stereolithography machines.

Course Content (Body of knowledge) -
  1. Computer Developed Parts Fabricated with Lasers
    1. Vector and Raster Engraving (Profiling)
    2. Cutting, Drilling and Slitting
    3. Multilayer Raster Engraving
    4. Template pattern cutting
  2. Computer generated parts or models fabricated by CNC Milling
    1. File Development
    2. Machine Programming
    3. Machine setup
    4. Part generation
  3. Computer generated parts fabricated by Fused Deposition Modeling
    1. File development
    2. Machine programming
    3. Machine setup
    4. Model or part fabrication
  4. Computer generated parts by Stereolithography
    1. File development
    2. Machine programming
    3. Machine setup methods
    4. Part or model fabrication
  5. Computer generated parts by 3D Printer
    1. File development
    2. Machine programming
    3. Machine setup methods
    4. Part or model fabrication
  6. Model or part surface finishing
    1. Surface preparation
    2. Finishing methods and materials
  7. 3D Modeling Equipment
    1. Kinematic model fabrication 3D modeling equipment
    2. Fabrication of part assemblies using multiaxis CNC machining and
    3. Fabrication of high tolerance parts using water jet cutting
    4. Fabrication of high tolerance parts using laser cutting
H.Case Study Project Planning Methods
  1. Developing Timelines
  2. Progress Reports
  3. Final Solution and Presentation
Methods of Evaluation -
  1. Quizzes and tests - objective, essay and performance - that measure student's ability to identify, explain, and perform basic CNC, Laser/Water cutting, Stereolithography, and 3-D rapid modeling equipment techniques and applications as covered in course topics.
  2. Design solutions that require student to interpret and analyze industrial methods and procedures for producing rapid 3D models and prototypes.
  3. In class demonstrations and design presentations that demonstrate student's ability to solve a problem by using the appropriate equipment and applying the correct techniques and then analyzing the merits of the solution.
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, lecture/lab, group laboratory work.
 
Lab Content -
  1. The student will design a package in CAD and build it on the laser.
  2. The student will CNC cut a 3D sign of their initials out of urethane foam.
  3. The students will design a game piece in CAD and build it on the Fused Deposition Modeling machine.
  4. The student will design a 1 tall perfume bottle in CAD and build it on a stereolithgraphy machine.
  5. The student will design and create a working assembly and espresso cup in CAD and build it on a 3D printing machine.
  6. The student will scan a clay sculpture into the computer, manipulate it's size and print it on an RP machine.
  7. The student will sand, prime, and paint a rapid prototype model until it has a gloss surface.
 
Types and/or Examples of Required Reading, Writing and Outside of Class Assignments -
  1. Writing: Create presentations relating design criteria and explain the way in which the design meets consumer needs and demographics. Assignments in which students describe current trends in new modeling equipment and techniques.
  2. Other: Generate three-dimensional computer-aided parts including programming and setup of multi-axis CNC mills for part fabrication. Set up and form a part on fused deposition modeling equipment and on stereolithorgaphy modeling equipment.
  3. Oral: Present design solutions for critique and explain their experience in the use of various techniques and elaborate the merits of each. Class design critiques and class discussions explaining their experience in the use of various techniques and elaborate the merits of each.