Overview
Workload: ● ● ● ○ ○
Previous Knowledge: ○ ○ ○ ○ ○
Current Knowledge: ● ● ● ○ ○
Concepts
Sheet metal, metal laser cut, waterjet cut, bending
Software
Illustrator, Autocad, Intellimax by Omax
Assignments
Design and produce something with a digital fabrication process (incorporating computer aided design and manufacturing) not covered in another assignment, documenting the requirements that your assignment meets, and including everything necessary to reproduce it
Documentation
The hardest part about the wildcard week was to choose only one of the possibilities mentioned in class.
The default options included AR and VR, composites, electrical discharge machining, embroidery, inflatables and soft robotics, large format cutting, sheet metal and welding and waterjet cutting.
Although I was interest in most of them, I ended up choosing sheet metal cutting, given that it was the most useful for the final project as probably the most interesting for me in the future.
Ideating and Designing
1. The first step was to define the objects I wanted to make.
For my final project, I really wanted to use some parts of metal but I dind't know how to make it. So, this was a great opportuntity.
Basically, I focused on 4 components:
• Laptop Stand: one piece of flat metal + one piece of bended metal (connected by a wood dowel)
• Monitor Shelf: one piece of flat metal supported by 4 wood legs
• Stationery Module: 3 pieces of flat metal that will serve as a base for stationery components
• Laptop Stand: 45 metal pieces that create a grid for alingning components
2. After designing the 3D model, I created the flat version on Illustrator.
It is important to note that I had a version with all surfaces that should be bended and another use that was used for the machines, including only the cuts (.dxf file)
Cutting
1. Initially, we had available a 2'x2' sheet of steel (aprox. 1mm thick).
For this thickness, it was easy to cut using the laser cutter machine - 3D Fablight 3000.
2. Then, John helped me to convert the file and program the machine.
3. The cuts were very precise and fast. The only important consideration is that smaller pieces fell down from the surface and I had to look for them after the job finished.
4. Although the pieces were cut perfectly, I needed to use a thicker sheet of steel.
It was supposed to be possible to cut it with the same laser cutter. However, John suggested to use the waterjet and it was a great opportunity to learn a new technique.
The Omax 2652 Waterjet Cutter is a large machine that cuts ipt to 6" thick material by pushing high-pressure water mixed with an abbrasive material.
5. Again, I used the same .dxf file and setup with in the Omax software, which automatically generates the cutting path.
6. Then, I had a similar issue with the smaller pieces. Because the waterjet doesn't have a flat bed and it is in a water tank, it was not possbile to cut with the normal setup.
That's why we first cut the largest pieces.
7. The little metal square were cut using another bed with smaller gaps.
The trickiest part was that, every time that a few squares got cut, they started to move and it was risky for them to fell in the water tank. So I had to stop the machine multiple times in order to ensure that I would keep all the pieces.
Bending
1. After cutting, I had to bend some parts. To do that, I used the Finger Brake.
Essentially, I just needed to hold one part and push the handle to bend the other side. Also, there is a tool to use as reference to the angle you need.
*Two important learnings:
1. It is required to design thinking about the constrains you have when doing multiples bends. When I tried to bend a shelf, I ended up smashing one of the corners.
2. The thickness of the material can make it much harder to bend. For instance, the pieces cut on the water required much more strenght.
Finally, I got all pieces finished.
This has been one of the weeks I learned the most and fastest. I had never work with metal and it was great to see how different thickness and materials affect your ability to cut and bend your design.
Also, thinking about product design and development, I look forward to create more products using the skills I develop this week.
Files