Week 3 - Lecture

Detailed Component Design

Justin Rice
February 2, 2012

ME 24-688 Introduction to CAD/CAE Tools

 Week 2 Problem Set

• Ensure all week 2 problem set assignments

are submitted.

ME 24-688 Introduction to CAD/CAE Tools

 Open Q&A

• Open Q&A about week 2 topics

ME 24-688 Introduction to CAD/CAE Tools

 Quiz #1 – Week 1-3 Topics

• Quiz #1 during first 30 minutes of Tuesday’s

lab sessions on topics from weeks 1-3.

ME 24-688 Introduction to CAD/CAE Tools

 Lecture Topics

• Product Engineering Part 2

• Rapid Prototyping
• Designing for Manufacturing Intro
• Designing Styled Components
• Designing Plastic Components
• Case Study Examples

ME 24-688 Introduction to CAD/CAE Tools

 Product Lifecycle – Week 3

Portfolio Conceptual Product

Requirements
Management Design Engineering

Manufacturing
Engineering

Simulation &
Validation

Build &
Produce

Disposal & Maintenance Sales & Test & Quality

Recycling & Repair Distribution

ME 24-688 Introduction to CAD/CAE Tools

 3D Design Use
CNC
Manufacturing

Rapid
Prototyping

Automation

3D CAD Model
Design Detail
and Form

Visualization

Simulation /
Analysis

ME 24-688 Introduction to CAD/CAE Tools

 3D Design Use
CNC
Manufacturing

Rapid
Prototyping

Automation

3D CAD Model
Design Detail
and Form

Visualization

Simulation /
Analysis

ME 24-688 Introduction to CAD/CAE Tools

 Common Terms

• Rapid Prototyping
– General term for automatic
construction of a physical
prototype object on a machine.

• Rapid Manufacturing
– General term for the automatic construction of a physical object
that will be used as a production item.

• 3D Printing
– Process for creating 3D objects from a materials printer. Generally
more desktop and affordable machines.

ME 24-688 Introduction to CAD/CAE Tools

 How it Works
• Objet Overview
– http://www.youtube.com/watch?v=sNyIOPrXhd8
– http://www.youtube.com/watch?v=CEA2HaFqsVQ
– http://www.youtube.com/watch?v=B9VOwqtOglg

ME 24-688 Introduction to CAD/CAE Tools

 STL Files

• Industry standard file format used by

Stereolithography software to generate
information needed to produce 3D models
on rapid prototype machines.

ME 24-688 Introduction to CAD/CAE Tools

 3D Printing Applications

• Concept Models
– Used to evaluate, optimize, and
communicate your designs.

• Functional Prototypes
– Allow you to test in real-world environments and make decisions.

• End-use Parts
– Build small quantities of parts that are tough enough for production.

ME 24-688 Introduction to CAD/CAE Tools

 Benefits of Rapid Prototyping

• Time Savings
– Improve Design
– Increase Visualization

• Cost Savings / Reduction

– No prototype tooling and parts
– Small Qualities
– Detect design flaws early

ME 24-688 Introduction to CAD/CAE Tools

 Validate Design Form

ME 24-688 Introduction to CAD/CAE Tools

 Functional Prototypes

ME 24-688 Introduction to CAD/CAE Tools

 Considerations

• Tolerances
– +/- 0.005 inch or +/- 0.0015 inch per inch
whichever is greater

• Build Sizes
– 15” x 14” x 15” (Average)
– 36” x 24” x 36” (Large)

• Material Properties
– Wax Based Materials
– Plastic Based Materials (ABS, Polycarbonate)
– Metal Based Materials (Newer)
ME 24-688 Introduction to CAD/CAE Tools
 Companies

• Machine Providers
– Stratasys = www.stratasys.com
– 3D Systems = www.3dsystems.com
• Cubify = http://cubify.com
– Objet = www.objet.com

• On Demand Service Providers

– Quickpart = www.quickparts.com
– Proto Labs = www.protolabs.com
– RedEye = www.redeyeondemand.com

ME 24-688 Introduction to CAD/CAE Tools

 Case Study Examples

• Tape Wrangler Case Study

– http://www.youtube.com/watch?v=M_F6KlbFK4M

• Oreck Case Study

– http://youtu.be/9ipyauy81sU

ME 24-688 Introduction to CAD/CAE Tools

 3D Design Use
CNC
Manufacturing

Rapid
Prototyping

Automation

3D CAD Model
Design Detail
and Form

Visualization

Simulation /
Analysis

ME 24-688 Introduction to CAD/CAE Tools

 Design Detail and Form

• Complex and Styled Parts

ME 24-688 Introduction to CAD/CAE Tools

 Plastic Part Modeling Methods

• Solid Shell Method

• Surface Thicken Method

ME 24-688 Introduction to CAD/CAE Tools

 Designing Styles Parts

• Industrial design products like Autodesk®

Alias® support rapid creation and
manipulation of complex surfaces and
development of Class-A surfaces.

ME 24-688 Introduction to CAD/CAE Tools

 Design for Manufacturing (DFM)

• What is DFM?
– DFM is the process of proactively designing products to optimize all
the manufacturing functions to assure the best cost and quality.

• Why DFM?
– Lower development cost
– Shorter development time
– Faster manufacturing start to build
– Lower assembly and test cost
– Higher quality

ME 24-688 Introduction to CAD/CAE Tools

 Injection Molding Manufacturing

• The process consists of a mold that

normally has two halves that seal together
for the filling of melted plastic.

ME 24-688 Introduction to CAD/CAE Tools

 Injection Molding Machines

ME 24-688 Introduction to CAD/CAE Tools

 Good Plastic Injected Part Design

• Most critical factor is keep the part wall

thickness uniform throughout part.
• Have proper draft angle on part to ease
ejection from mold. (0.5 – 2 Degrees Normal)
• Avoid undercuts requiring slider cores when
possible to avoid complexity.
• Avoid sharp corners by adding radius.

ME 24-688 Introduction to CAD/CAE Tools

 Examples

ME 24-688 Introduction to CAD/CAE Tools

 Mold Analysis

• Autodesk® Moldflow® allows you to

simulate the filling of the injection molding
process to predict the flow of melted plastic.

ME 24-688 Introduction to CAD/CAE Tools

 Moldflow Benefits

• Identify Possible Defects

– Weld Lines & Sink Marks
– Warpage & Shrinkage

• Optimize Manufacturing
– Ensure Proper Injection Mold Design
– Material Selection

• Simulation
– Use as-manufactured material properties

ME 24-688 Introduction to CAD/CAE Tools

 Summary Process Example

• Step 1 = Conceptual Design

• Step 2 = Product Engineering
• Step 3 = Produce Rapid Prototype
• Step 4 = Make Required Improvements
• Step 5 = Simulate and Test Design
• Step 6 = Visualize Design for Final Approval
• Step 7 = Manufacture for Production

ME 24-688 Introduction to CAD/CAE Tools

 Franke - Case Study
Challenge
To maintain its competitive leadership position in the kitchen technology
industry, Franke needed a continuous digital pipeline for its product design
data.

Results
• Enabled users to validate
design and engineering
decisions as they worked,
minimizing the need for
physical prototypes.
• Reduced costly engineering
changes that previously were
discovered after the design
was sent to manufacturing.
• Helped provide quick and
effective communication
between diverse business
teams.
“Autodesk Inventor has played a critical
role in helping us increase development
cycle speed for new products. The ability
to use digital prototyping to virtually
explore a complete product before it is
built saves us time at every step of the
product development cycle, from the
industrial design phase though the
manufacturing process.”
Christian Sperka
Chief Information Officer
Franke
Switzerland

ME 24-688 Introduction to CAD/CAE Tools

 Jede Automater - Case Study
Challenge
To stay ahead of increasingly tough competition in the marketplace, Jede
Automater sought an efficient development workflow with the Autodesk
solution for Digital Prototyping.

Results
• Designed, visualized, and
simulated its products in
Inventor to significantly
reduce time to market.
• Reused design data and
automated the release and
change management
processes using Vault
Manufacturing.
“By virtually exploring our products
before they become real, we are able to
order materials at an early stage and
easily stay within our budgets. It is quite
clear that Digital Prototyping saves us
both time and money.”
Marcus Berntson
Development Manager
Jede Automater
Sweden

• Collected direct feedback

from customers with highly
realistic renderings.

ME 24-688 Introduction to CAD/CAE Tools

 Open Q&A

• Open Q&A time for discussion on topics

ME 24-688 Introduction to CAD/CAE Tools

 Break

• 5 Minute Class Break

ME 24-688 Introduction to CAD/CAE Tools

 Live Instructor Demo

• Live Instructor Autodesk Inventor Demo

ME 24-688 Introduction to CAD/CAE Tools

 Guided Lab Project 1

• Guides instructions for creation various fillet

feature types.

ME 24-688 Introduction to CAD/CAE Tools

 Guided Lab Project 2

• Guided instructions for modeling plastic

component case.

ME 24-688 Introduction to CAD/CAE Tools

 Guided Lab Project 3

• Guided instructions for modeling plastic

component case.

ME 24-688 Introduction to CAD/CAE Tools

 Assignment
• Plastic Part Design Essentials 2011Course
– Plastic Part Design Basics Unit
– www.myigetit.com

ME 24-688 Introduction to CAD/CAE Tools

 Problem Set Assignment

• Model detailed plastic molded part with

various features.

ME 24-688 Introduction to CAD/CAE Tools

 Demo Topics

The following slides are used for key topics for live
demo.

ME 24-688 Introduction to CAD/CAE Tools

 Creating Draft Features
• Draft

Ribbon: Model tab | Modify panel | Draft

Keyboard Shortcut: D

• Draft Mini-Toolbar Options

ME 24-688 Introduction to CAD/CAE Tools

 Work Features
• Work Point

Ribbon: Model tab | Work Feature| Point

Keyboard Shortcut: .

• Work Axis

Ribbon: Model tab | Work Feature| Axis

Keyboard Shortcut: /

• Work Plane

Ribbon: Model tab | Work Feature| Plane

Keyboard Shortcut: ]

ME 24-688 Introduction to CAD/CAE Tools

 Creating Rest Features
• Rest

Ribbon: Model tab | Plastic Part | Rest

ME 24-688 Introduction to CAD/CAE Tools

 Creating Grill Features
• Grill

Ribbon: Model tab | Plastic Part | Grill

ME 24-688 Introduction to CAD/CAE Tools

 Creating Boss Features
• Boss

Ribbon: Model tab | Plastic Part | Boss

ME 24-688 Introduction to CAD/CAE Tools

 Creating Lip Features
• Lip

Ribbon: Model tab | Plastic Part | Lip

ME 24-688 Introduction to CAD/CAE Tools

 Creating Snap Fit Features
• Snap Fit

Ribbon: Model tab | Plastic Part |Snap Fit

ME 24-688 Introduction to CAD/CAE Tools

 Creating Fillet Features
• Revolve

Ribbon: Model tab | Modify| Fillet

Keyboard Shortcut: F

• Extrude Mini-Toolbar Options

– OK – Style
– Apply
– Cancel

– Selected
– Radius Value – Options

– Fillet

ME 24-688 Introduction to CAD/CAE Tools

 Creating Rib Features
• Rib

Ribbon: Model tab | Plastic Part | Rest

ME 24-688 Introduction to CAD/CAE Tools

 Solid Body Modeling
• Multi-body parts are a versatile and powerful approach to
skeletal modeling.
• The versatility and power of multi-body parts is expanded with
the ability to derive multiple bodies into a single part, conduct
Boolean operations between solid bodies, split a solid body into
two bodies, and move bodies within the part.

ME 24-688 Introduction to CAD/CAE Tools