Project 1: Manufacturing
Before you begin…
Please check that you have fully completed all of the following before starting this project.
- Journal #1 - Engineering Design Process
- Journal #2 - 3D Printing
- Tutorial #1 Sign Off - Setting Up Google Sites
- Tutorial #2 Sign Off - Using Vernier Calipers
- Tutorial #3 Sign Off - 3D Modelling in TinkerCAD
- Tutorial #4 Sign Off - 3D Printing with Bambu Studio
- Tutorial #5 Sign Off - Using a Hobby Knife
- Tutorial #6 Sign Off - 2D Design in TinkerCAD
For your first project in the class, you are asked to create a physical object that demonstrates: one additive manufacturing process and one subtractive manufacturing process. At least one of these processes should be a digital fabrication process (i.e. using a computer to control the tool path of a machine, for example: a 3D printer nozzle or a blade on the cricut).
Available Materials#
- PLA Filament, various colours
- Adhesive Vinyl, black/red/white
- Hot Glue
- Cardboard
- Printer Paper
- Glue Stick
- Elastic Bands
- Chord/String
There is no requirement to use any of the above materials. Materials brought in from home are allowed so long as they are safe and help you meet the project criteria.
Constraints#
- Your final object should not consume more than 50g of filament
- Your final object should not consume more than 100 mm x 300 mm of vinyl
- Your final object should not consume more than 1/2 stick of hot glue
- Your final object should not be larger than 250 mm in any dimension
- Your final object should serve at least a single purpose
- All designs need to be appropriate for school (no weapons)
Note that material constraints do not apply to prototypes, but if you are wasting material on designs that have not been effectively iterated on, you will receive restrictions on printing and cutting.
Success Criteria#
To be successful in this project, your process/product must:
- Utilize the engineering design process to plan, ideate, iterate and improve
- Use calipers to measure
- Demonstrate an understanding of at least one additive manufacturing process
- Demonstrate an understanding of at least one subtractive manufacturing process
- Be well documented and published on your site
Rubric#
| Criteria | Level 4 (Exemplary) | Level 3 (Considerable) | Level 2 (Some) | Level 1 (Limited) | Level 0 (Not Met) |
|---|---|---|---|---|---|
| Engineering Design Process | Demonstrates a thorough, highly reflective design process, commenting on each step of the cycle, with at least 2 purposeful iterations and clear refinements. | Documents and reflects on almost 2 full cycles of the EDP. | Documents and reflects a full cycle of the EDP. | Documents and reflects on part of one EDP cycle. | Does not demonstrate the design process; no evidence of planning, ideation, or iteration. |
| Use of Vernier Calipers | Demonstrates high precision with calipers, resulting in suitable tolerances, seamless real-world fits, or precise reverse engineering. | Accurately uses Vernier calipers to collect precision dimensions and transfer them into design models. | Uses calipers with some accuracy; minor dimensional discrepancies exist in CAD models or physical parts. | Uses calipers with limited accuracy, resulting in notable dimensional errors or poor fit. | Fails to use Vernier calipers, or measurements are absent/entirely inaccurate. |
| Additive Manufacturing Process | Demonstrates advanced understanding; optimizes slice settings, print orientation, and designs for FDM printing. | Demonstrates clear understanding of 3D printing; part is clean and structural. | Demonstrates some understanding of 3D printing; part is functional with minor printing/slicing flaws or missed considerations. | Demonstrates limited understanding of 3D printing; print has major structural/aesthetic defects | Additive process is missing, or fails to yield a functional component. |
| Subtractive Manufacturing Process | Demonstrates high craftsmanship and precision in subtractive techniques; flawless edges, efficient material layout, and professional finishing. | Demonstrates clear execution of subtractive techniques; clean enough cuts. | Demonstrates some execution of subtractive techniques; cuts are functional with aesthetic rough edges or material waste. | Demonstrates limited execution of subtractive techniques; cuts are rough or inaccurate. | Subtractive process is missing or incomplete |
| Documentation & Portfolio Publishing | Portfolio documentation is exemplary and executive-ready; thoroughly details design choices, challenges, pictures, CAD files, and clear reflections. | Documentation is well-organized, complete, with process photos, CAD files, and reflections. | Documentation provides a basic summary, but lacks detail in process reflections or supporting visuals. | Documentation on Google Site is incomplete, poorly organized, or lacks key photos | Documentation is absent or project is not published to the student’s site. |
| Functionality & Project Constraints | Object delivers a highly effective, elegant solution to a real-world problem while maximizing utility within all project constraints. | Object serves a clear, intended purpose and adheres to all safety, size (≤250 mm), and material constraints. | Object serves a basic purpose and meets most constraints, though minor rule or size overages exist. | Object attempts a purpose but is non-functional, fragile, or breaches multiple size/material constraints. | Object lacks purpose and/or exceeds size/material bounds. |
Tips for Getting Started#
Think of a Simple Problem to Solve#
Did something small break? Did you lose something small that could only be replaced by having to buy a whole new set? Think small at first, it’s a lot harder to engineer a fix for something than you might think!
Think Carefully About Your Constraints#
What materials are you working with? What about your design/CAD knowledge? How might this limit what designs you are able to produce for this project?
Make Something Pretty#
Your object could be cosmetic, so long as you have an intended audience.
Reverse Engineer Something#
Take something that already exists, something a previous student has made, something in the classroom, and try to create it yourself using nothing but your eyes and tools! Sketch out the object and collect as many measurements as possible using your calipers, and then try to recreate the object in TinkerCAD.
Interface with the Real World#
Is there any object you have that you could augment with a 3D print or vinyl cut sticker?
Keep it Simple, Student (K.I.S.S.)#
Your first project isn’t meant to be the grand finale for the class. Pick something that is feasible for the amount of time you have. Don’t spread yourself too thin trying to create something massive, as you won’t even have enough time to get the first iteration done, let alone improve it. Also, the best solutions for problems are usually the ones that are the most simple, don’t overengineer when it isn’t needed!
The Most Important Thing#
This project is about developing your ability to work through the Engineering Design Process. Failure is part of the process and is a good sign that you’re doing things right. What you “hand in” will not be finished, regardless of how much time you put into it, and that’s okay! So long as you have something to document, reflect, and talk about iterating on, you are doing exactly what you need to! The best thing you can do each class is make some progress through your processes and ensure you are documenting every step, every problem, and every thing you noticed while testing. Remember to review the rubric to see how you will be evaluated.