Design Realization

lecture 9
John Canny
9/23/03

Last Time
More on kinematics and IK.
Some concepts from dynamics.

This time: Manufacturing &

Materials
Manufacturing is undergoing a revolution:
Traditional methods:

Casting, molding, fusing, slumping

Milling, lathing (non CNC-versions)
Stamping
Rolling, extrusion

Shape is write-once (not programmable) in

these methods.

Next-wave Manufacturing
Reprogramming shape:
CNC machining:
A computer outputs a path for a
cutting tool to create a specified
surface.
Not new, but now inexpensive,
PC-based.
Plastics, wood, metal, glass.
Flashcut 2000, XYZ-axes, 9x7x6.5, $2895

Milling
Milling involves a moving XYZ head that cuts
into the workpiece:
Bits can achieve different
finishes.

Lathing
Lathes cut circularly symmetric parts.
Shafts, furniture, fasteners, lenses.
Can also do grinding and polishing.

Milling Example
CNC milling example
(Deskproto web site)
Finish is quite smooth
ballnose cutting tool.

Lots of waste, but can

be recycled!

Next-wave Manufacturing
PC-boards:
Created with CAD tools.
Photographic reproduction:
Low cost in volume.
High complexity possible.
Multi-step process, BUT:
Web-based services have 24-hour turnaround,
low cost.

Next-wave Manufacturing
CNC Laser cutter:
X-Y axes control a powerful laser.
Fine line (0.007 or better).
Positioning to 1000 dpi,
Some control of depth:
Engraving as
well as cutting.
Moderate cost:
$10,000 Versalaser
16x12 workspace.

Laser Cutter Capabilities

Precision is good enough to make smooth
sliding surfaces (gears).
Layering can be used to make
3D surfaces (very popular for
architectural models).
Can even make PCBs
by etching metal
from clear plastic!

Other 2D Cutting Technologies

Lasers can cut metal, but not
easily
Power limits, need to deal with
material removal.

Plasma cutters use an

electrically-generated plasma
jet to cut
Sweeps away material.

Plasma Cutters
Thin shapes in a variety of metals.
Torchmate 3 machine
is $10,000 for 4x8
workspace.

Water Cutters
Similar idea to plasma but based on highpressure waterjet.
Cleaner method: water plus metal can be
collected.
Cost??

3D printers
A variety of 3D printing techniques have
appeared in the last few years.
SLA: Stereolithography: laser curing of
liquid plastic.
SLS: Selective Laser Sintering: similar, laser
fuses powder.
LOM: Layered Object Modeling: laser cuts
paper one layer at a time.
FDM: Fused Deposition Modeling: a thread
of plastic is melted through a moving head.

Stereolithography: SLA
Earliest 3D method, based on UV-set polymers.
Resolution quite good: 0.002 layers.
Curing needed before
part can be used.

LOM: Laminated Object

Modelling

FDM: Fused Deposition Modelling

FDM is one of the most
versatile 3D methods
Many materials can be used:
solvent-based or thermoplastics.
Requires X-Y-X motion (like
a CNC machine).
Stratasys machines start at
$30,000

Roll-your-own 3D Printers
Material feeding heads are
commercial modules.
Microfab makes heads for
solvent-based and thermoplastics.

Add a CNC XYZ-stage to

create your own printer.

Roll-your-own 3D Printers
Polymer electronics is printable with microfab
heads, working on actuators.
Potential for printing complete electromechanical systems.
Two prototype printers
at Berkeley.

3D Printer Disadvantages
Slow! Adding material is much slower than
removing it.
Speed scales very poorly with resolution:
double resolution and decrease speed by 8x.
Laser 3D methods faster (than other heads)
for equivalent resolution, but limited
materials.

3D Printing Data
The standard 3D printing format is STL.
Available as an output option for most CAD
tools, as a 3rd-party translator for Maya.
Then process-specific CAM software
(Computer-Aided Manufacturing) creates a
tool control file:
Tool path for milling and lathing.
Slices and support structures for 3D printers.

Summary
CNC machines provide shape programmability.
Lathes and mills provide traditional shaping.
Layered methods can create almost unlimited
shapes, but slowly.
2D and 3D shaping methods generally based
on CNC motion of an active head.
Architecture of shaping machines is open:
movement and heads are available separately.