How To Design A 3D Model For A 3D Printer

Transcription

1 Poznan RAPIDPROTOTYPINGSERVICE MODEL BY THE CDIO *) EDUCATIONAL FRAMEWORK *) Conceive Design Implement Operate Lauri Tenhunen Seppo Aarnio

2 CDIO INNOVATION PROCESSES OF INDUSTRY RPS ELEMENTS OF RPS MODEL RP- TECHNIQUES (Rapid Prototyping Service Model)

3 CDIO WHAT IS CDIO?

4 CDIO AN INNOVATIVE EDUCATIONAL PROGRAM FOR PRODUCING THE NEXT GENERATION OF ENGINEERING LEADERS. IT FORMS THE BASIS OF YOUNG UNDERGRATUATE EDUCATION. CDIO was developed in MIT in the late nineties

5 WHY CDIO?

6 ENGINEERING EDUCATION CDIO REAL-WORLD DEMANDS IT IS THE JOB OF ENGINEERS TO BE ABLE TO ENGINEER

7 Graduatingengineersshouldbeableto Conceive-Design-Implement-Operate complexvalue-addedengineering systems in a modernteam-basedenvironment. Prof Crawley, MIT

8 STRUCTURE OF THE CDIO SYLLABUS

9 Teamwork Communication Communication in Foreign Languages Knowledge of Underlying Sciences Core Engineering Fundamentals Advanced Engineering Fundamentals Engineering Reasoning and Problem Solving Experimentation and Knowledge Discovery System Thinking Personal Skills and Attitudes Professional Skills and Attitudes Fig.1 CDIO Blocks of knowledge

10 Fig. 2 CDIO Syllabus within the EBC and the ESC ESC

11 BENEFITS OF CDIO Fresh ideas Increased cooperation Theory into praxis Students will learn the laws and language of business world Working together in teams with different people

12 INNOVATION PROCESSES OF INDUSTRY PRODUCT INNOVATIONS IN ENTERPRISES

13 PRODUCT DEVELOPMENT CONSISTS OF SEVERAL STEPS Fig.3Three phases of a simplified innovation process

14 RP- TECHNIQUES RAPID PROTOTYPING PERFORMANCE

15 FUNDAMENTAL FABRICATION PROCESSES AM C K Chua, K F Leong, & C S Lim: Rapid Prototyping: Principles and Applications Fig. 4 19/10/2010 S.AARNIO

16 Additive manufacturing (AM) is defined by ASTM as the process of joining materials to make objects from 3D model data, usually layer upon layer. RP is one form of AM. It is used in making prototypes

17 AllRP techniquesbasicallyfollowthe same5-step system: 1. Creatinga3DCADmodelofthedesign 2. ConvertingtheCADmodeltoSTLformat 3. Slicing the STL file into thin cross-sectional layers 4. Constructing the model one layer atop another 5. Cleaning and finishing the Model To prototype successfully you need to select an appropriate technical RP tool and form an RP team.

18 CAD MODEL CREATION: using a CAD software package or by using a laser scanner or a Coordinate Measuring Machine (CMM). ( Reverse engineering ) 19/10/2010 S.AARNIO

19 CONVERSION TO STL FORMAT: The standard data interface between CAD sofware and the machine is the STL-format (Stereolithography). An STL-file approximates the shape of a part using triangular facets. Small facets produce a high quality surface. 19/10/2010 S.AARNIO

20 Since the.stl format is universal, this process is identical for all of the RP build techniques. SLICING THE STL FILE: The program may also generate an auxiliary structure to Support the model during the build 19/10/2010 S.AARNIO

21 19/10/2010 S.AARNIO SUPPORT MATERIAL

22 LAYER BY LAYER CONSTRUCTION: The fourth step is the actual construction of the part. Using one of several techniques (described later) RP machines build the model layer by layer. The material s initial states are: LIQUID SOLID or POWDER 19/10/2010 S.AARNIO

23 GENERAL ADVANTAGES OF RP Practically no limitations to the form to be produced. Reduction in time and cost (could range 50 90%. Wohler) Errors and flaws can be detected at an early stage. RP/RM can be used in different industries and fields of life (medicine, art and architecture, marketing..) Discussions with the customer can start at an early stage. Assemblies can be made directly in one go. Material waste is reduced. No tooling is necessary. The designers and the machinery can be in separate places. 19/10/2010 S.AARNIO

24 APPLICATIONS OF AM Technology 19/10/2010 S.AARNIO

25 The task was to test different alternative INTAKE MANIFOLDS. The parts (three) were made of Windform XT with laser sintering. By using SLS the time from desktop to product took only about 10 % of the time earlier. 19/10/2010 S.AARNIO

26 Wind tunnel tests 19/10/2010 S.AARNIO

27 Medicine Models of skulls etc can be used for training of surgical operations 19/10/2010 S.AARNIO

28 Parts made of titamium are used for replacements 19/10/2010 S.AARNIO

29 These siamese twins were succesfully separated. The operation was planned with models of the skulls. 19/10/2010 S.AARNIO

30 Architecture 19/10/2010 S.AARNIO

31 RP/AM-TECHNOLOGIES Stereolithography (SLA) Fused Deposition Modeling (FDM) Selective Laser Sintering (SLS) Laminated Object Manufacturing (LOM) 3D Printing Direct metal laser sintering (DMLS) 19/10/2010 S.AARNIO

32 STEREOLITHOGRAPHY SLA 19/10/2010 S.AARNIO

33 FUSED DEPOSITION MODELING FDM 19/10/2010 S.AARNIO

34 SELECTIVE LASER SINTERING SLS 19/10/2010 S.AARNIO

35 LAMINATED OBJECT MANUFACTURING LOM 19/10/2010 S.AARNIO

36 RPS BY THE CDIO FRAMEWORK

37 To formulate the RPS model logically, we will first arrange the needed elements into groups of objects (nouns) and actions (verbs) and then describe the three processes simultaneously

38 THE LIST OF OBJECTS (NOUNS) WILL INCLUDE FOLLOWING: The RP team (including students and experts) The customer and its agents The target product and its properties The RP technique chosen The Prototype The time schedule and the budget THE LIST OF ACTIONS (VERBS) WILL INCLUDE FOLLOWING: Discussing the task and choosing the innovation level Regulating and adjusting the RP process during work Changing, Developing and Iterating the Prototype Testing the prototype solutions Finishing the best prototype Saving the necessary CAD documents budget Consulting and Advising by experts Learning to conceive, design, implement and operate the RP process by the students Making decisions by the customers Next slide (Fig. 5) will demonstrate the three simultaneous processes.

39 Test marketing Commercial iterations Product development FIGURE: RPS in relation to CDIO Engineering Education and Enterprise product development function 3. Evaluation Learning outcomes 4. Penetration Decisions Marketing, Production Final Prototype Implementing Operating Designing 2. Conceiving 1. Project idea conception Product Design Evalution Planning Planning with CAD RP modelling Technical iterations Product conception Requirement Analysis Fig. 5

40 The students involved in the RPS process are able to adopt the techniques of RP engineering and also fundamentals of engineering service processes and business to business service sales.

41 RP team, proper for CDIO education framework within a university, would include: competent teacher(s), group of students, programmer(s), enterprise representatives.

42 Enterprise Actions Assignment Idea Conception Participation Evaluation Product targets Learning targets Fig. 6 RPS Model and Actions. The model includes four elements: The team, the system, the product and the enterprise Team Actions

43 Enterprise Actions Assignment Requirements Planning CAD models Idea Conception Participation Evaluation Product targets Learning targets Mentoring CAD modelling Evaluation Team Actions

44 Enterprise Actions Assignment Evaluation Planning Feedback Requirements RP modelling Iterations Planning CAD models Developing physical models Idea Conception Participation Evaluation Product targets Learning targets Mentoring CAD modelling Evaluation Team Actions

45 Enterprise Actions Assignment Evaluation Planning Feedback Testing: Technical and commercial Final Prototype Requirements Idea Conception Planning CAD models RP modelling Iterations Participation Evaluation Product targets Learning targets Developing physical models Mentoring CAD modelling Evaluation Proposal Approval Modifications Team Actions

46 Enterprise Actions Testing Decisions Assignment Evaluation Planning Feedback Testing: Technical and commercial Final Prototype Final Product Requirements Idea Conception Planning CAD models RP modelling Iterations Participation Evaluation Product targets Learning targets Developing physical models Mentoring CAD modelling Evaluation Proposal Approval Modifications Evaluation Learning outcomes Team Actions

47 CDIO INNOVATION PROCESSES OF INDUSTRY RPS RP- TECHNIQUES

48 BY THE USE OF CDIO EDUCATIONAL FRAMEWORK WE CAN EDUCATE PROFESSIONAL ENGINEERS WHO ARE: Technically competent Socially aware and Entreprenially astute professionals, who will become the next engineering leaders

49 ANY QUESTIONS?

50 THANK YOU FOR YOUR ATTENTION HAVE A NICE DAY