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ClassWork / Designing-For-Digital-Fabrication-S11
Designing for Digital Fabrication MasterCam assignment:
CNC chair assignment :
Laser assignment- Light / Image:
Week 3 note - Scriptographer is a scripting plugin for Adobe Illustrator. It gives the user the possibility to extend Illustrator’s functionality by the use of the JavaScript language. Week 2 assignment, 2D drawing:
Research assignment:
de la Torre, Belisario - Hot-wire foam cutter
      
Foam Cutting Services:
Additional Information:
Alden, Chris - CNC Drill
Van Sice, Corrie - CNC LatheBlog entry on the CNC Lathe
Phillips, David - CNC Multiaxis machining (3 + axis)MultiAxis Machining AKA Rotational Milling AKA 3/4/5/9axis Machining CNC tools that move either the CNC tools in a directional or rotational XYZ axis or also include rotating the manufactured part in an XYZ axis. This reduces the time of manufacturing, otherwise the parts would need to be manually turned and aligned. MultiAxis' milling process uses either water jet cutting or laser cutting. Multiaxis machining specializes in those hard to reach spaces and can produce curved holes. Examples:    File Formats: .IGES, .DWG, .DXF, .SAT, .SLDPRT and .SLDDRW. These files are then converted to G-Code. Sites for New York State:
NOTE: Most Multi Axis milling lies in the nether regions of New York or beyond. Kontraptionist is the closest one I found and it is 4-axis.
Borenstein, Gregory - CNC 3 axis machining
Moves a spinning milling cutter as well as the work piece to shape the piece into the desired shape. Two types: vertical and horizontal based on orientation of the spindle (the part that rotates). Vertical can be either turret or bed. - turret design is more versatile but only works at small scale  horizontal: "a heavy workpiece needing machining on multiple sides lends itself to a horizontal machining center"  Videos DIY 3-axis Mill from MIT Media Lab Tarus Heavy Duty 3-axis vertical mill Shopbot ITP's CNC is a Shopbot PRStandard (detailed specs) DIY buy your own, only $24K for the Grizzly! or $10k for the horizontal model There's also an Instructable:  Instructables desktop 3-axis CNC mill And a DIY kit: Zen Toolworks Swarf Mills produce "swarf": metal scraps left over by milling.
What do the parts look like?    World's 2nd most expensive soup spoon File Formats IGES, DFX, DWG and PDF files Materials Common Metals: Aluminum, Brass, Bronze, Carbon Steel, Cold Rolled Steel, Steel Exotics: Hastelloy, Inconel, Monel, Molybdenum Plastics: Delrin, Nylon, Plastics, Polyethylene, Teflon New York services Most ITP-ish: Kontraptionist Clayton, Joshua - CNC Router
Manriquez, Marko - CNC turret punch
CNC Turret Punch Press Fabrication Method: A punch press is a type of machine press used to cut holes in material. It can be small and manually operated and hold one simple die set, or be very large,CNC operated, with a multi-station turret and hold a much larger and complex die set (up to 60+). Punching is a metal forming process that uses a punch press to force a tool, called a punch, through the workpiece to create a hole via shearing. The punch often passes through the work into a die. A scrap slug from the hole is deposited into the die in the process. Depending on the material being punched this slug may be recycled and reused or discarded. Punching is often the cheapest method for creating holes in sheet metal in medium to high production. When a specially shaped punch is used to create multiple usable parts from a sheet of material the process is known as blanking. In forging applications the work is often punched while hot, and this is called hot punching The punch press is used for high volume production. Cycle times are often measured milliseconds. Material yield is measured as a percentage of parts to waste per sheet processed. CAD/CAM programs maximize yield by nesting parts in the layout of the sheet. CNC presses vary considerably in size and speed. The smallest, and therefore least versatile of the group are those with 20 or fewer tools in the turret, 20 tons or less of press capacity and table size of 40 in. (1 m) square or less.Intermediate-sized units may carry up to 60 tools, have up to 30 ton press capacity, and usually use a table of 50 in. (1.3 m) square. Larger machines carry as many as 72 tools, provide up to 50 tons of capacity, and feature table sizes as large as 60 in. (1.5 m) x 70 in. (1.8 m). A punch is less flexible than a laser for cutting compound shapes, but faster for repetitive shapes (for example, the grille of an air-conditioning unit). A CNC punch can take 600 strokes per minute. Operational speeds range from 80 to about 300 hits per minute (hpm). This rating is based on the one-inch movement of workpiece material between each "hit" or workstroke. The punch force required to punch a piece of sheet metal can be estimated from the following equation: F = 0.7tL(UTS) Where t is the sheet metal thickness, L is the total length sheared (perimeter of the shape), and UTS is the ultimate tensile strength of the material. Images and Videos:  ,    ,    
Materials:
Punch Stampings :
Special Design Considerations: To optimize processing time and material utilization, it is common for parts to be ganged or nested during turret press production. After punching, the sheet is agitated and the individual parts break apart and are stacked, ready for further processing, without having to be cut apart in a separate operation. The parts are therefore known as "shaker parts" or "shake aparts." Burr Direction. A burr, no matter how small it may be, inevitably is formed when a punch pierces sheet metal. Burr direction is important to the knowledgeable designer because it may be possible to plan the product so that the burr side of the part can be completely concealed--safely hidden from the user--thus saving the cost of deburring in a belt sanding operation. Flatness. The flatness of a workpiece is unavoidably affected by stresses induced and released during punching operations. Generally speaking, the more punching performed on the workpiece, the more bow or "oil canning" distortion is generated. Designs involving closely spaced hole patterns. and where more than 25% of the material is removed by punching, are subject to flatness distortions beyond acceptable levels. Depending on machine make, type and condition, the plus-minus feature tolerance may vary from ±0.005 in. (0.13 mm) to ±0.015 in. (0.38 mm). Program corrections can often be used to improve the inherent machine inaccuracies. National, on-line and local service providers: 2-4 week lead time usually
Pricing, Cost Optimization, per parts, and if there is a tooling/ setup cost:
File type requested for fabrication(DXF, STL…): Varies, usually DXF, Solidworks, AutoCAD, etc. Doherty, Michael - CNC Wire bending
Tchieu, Mindy - Water Jet Cutter Instead of a blade, a water jet cutter uses a stream of high-pressure, high-velocity water. Therefore, it's beneficial when you're cutting something that's sensitive to high temperatures, because it doesn't disturb the chemical markup of the material. Common materials cut are: rubber, foam, plastics, stone, tile, metals, food, paper, composites. It can cut material up to 18-inches thick. You cannot cut tempered glass (glass that has been treated so it's much stronger than normal-- I didn't know what this meant so figured someone else might not either), diamonds, and certain ceramics. The water cutter can do a wide variety of cut widths, called kerf. Typically if it's a wider width cut (0.04" to 0.05") an abrasive, such as garnet, will be added. Cuts can go as thin as .007, the width of a human hair. Edge quality is done on a scale of 1 to 5. 1 is the most coarse, and is recommended for large items, and 5 gives you a smooth, clean finish. Another neat thing about the water cutter is that It's "green" because it doesn't produce any hazardous waste and it recycles the water and garnet in a closed-loop cycle. Also it eliminates bad fumes and toxins from cutting materials such as asbestos and fiberglass, creating a healthy work environment for all. TL;DR VersionA water jet cutter is basically liquid sandpaper. Things you can cut with a water jet cutter: Rubber, foam, plastics, composites, stone (cuts this very well), tile, brass, bronze, steel Things you can't cut: Tempered glass, diamonds, certain ceramics How do I get something cut?
Here are a few places in the NY area that do water jet cutting: Ferra Designs
ACS Waterjet
Letterama
Mangahas, Minette - Industrial laser cutter (Nd, Nd-YAG)Intro: The Glass Engraver  The word LASER is an acronym: Light Amplification by Stimulated Emission of Radiation A laser is a light generator and amplifier that generates a single wavelength or color of light. Laser cutting uses a beam of infrared light or heat, focused to a small and intense spot to vaporize or melt a whole through a workpiece. Because laser light is a single wavelength it does not diverge, or spread out, as quickly and can be focused to a much smaller spot than ordinary white light. Comparing the power density between an incandescent bulb and a laser.   A 100 Watt Incandescent Bulb Focused to 1cm spot (0.4") Power Density = 127 Watts /cm2 A 100 Watt Laser Focused to 150 micron spot (0.006") Power Density = 550,000 Watts /cm2 (Image: PRCLaser.com) There are several types of Industrial Laser Cutters: - Solid state JK Nd:YAG Lasers and JK Fiber Lasers lasers can be used to cut metals, some ceramics and plastics, and graphite composites. - CO2 lasers address thin metal, paper, wood, plastic, fabrics, and other non-metal cutting applications. http://www.youtube.com/watch?v=AU7qPua_esw&feature=player_embedded The advantages of Laser Cutting include: Applicability to a wide range of materials and thickness Narrow kerf widths High speeds Consistent weld bead Very high repeatability Very high reliability Low operational costs--Easily automated and programmable Flexibility in changeovers Reduced tooling costs and reduced setup times Non-contact process (no tooling wear or breakage, minimal material distortion) Versatility (the same tool can also be used for laser drilling and laser welding) Capacity for high degree of beam manipulation (true 3-D cutting) Only requires access to one side of part No filler material (typically)  A laser cutting system has three major sections: 1) The Laser: Generates a round beam 1/2" - 1.2" (12 - 30mm) in diameter. First pulses to drill or pierce a whole through the workpiece. Then will output variable power based upon the material being cut and desired process speed. 2) The Beam Delivery: Transmits or delivers the beam to the focusing head via a series of mirrors called "beam benders". The focusing or cutting head uses a lens to focus the beam down to a spot 0.004" - 0.010" (100-250 microns). The focused laser beam will vaporize and or melt a small area of the workpiece. A pressurized gas, or "assist gas", will be added beneath the lens coaxially with the laser beam to push the molten material out of the cut zone. Cutting Head   Typical lens focal lengths for laser cutting are 3.75", 5", 7.5" and 10". The choice of lens will depend on the material type and thickness to be cut. Beneath the lens, a pressurized assist gas is injected to help remove material from the cut zone. There will usually be an interchangable nozzle attached to the bottom of the cutting head that allows the user to change the dynamics of the assist gas jet for different materials. Critical parameters to consider on the cutting head are: Lens Focal Length Lens, or focal spot standoff from the material Nozzle diameter Nozzle standoff from material Standard file type for fabrication depends on the company, most accept: CAD (DXF, DMG), Rhino, Illustrator. Photoshop, TIFF or JPG files may have a set-up fee. Materials commonly supported: Papers & Chipboard Plastics Wood Eco-Friendly Materials, like cork, bamboo Fabrics & Leather Glass Stone Metal Materials often not supported: PVCs, including Sintra PVC Foam Board, Polycarbonate Plastic Local Resources: (Other than AMS) Prototope, 349 Greenwich Street #5, New York ; (212) 431-7776, info@prototope.com, ($15 set-up fee, no minimum order, no glass or metal, 12"x24" bed, up to 1/4" thick) Kennedy Fabrications Architectural Models, 318 West 39th Street, New York; (212) 229-0722, laser@kennedyfabrications.com, ($150/hr, $100/hr to convert files, $120 min order, laminate PVC ok, bed sizes include 18"x24", 24"x48" and 48"x48"). Fine Laser Cut, 151 W 47th Street, New York; (212) 302-6073, info@finelasercut.com, (precious metal laser cutting, 7"x7" max, up to 1/8" thick, no min, no set-up fee, Illustrator file preferred). Other Resources: Length Width Height, Long Island B & H Precision Fabrications, Inc, Bohemia, NY Maloya Metal Fabrication, Commack, NY (steel, steel alloys, brass, aluminum) Some Reference Links: GSI Lasers http://en.wikipedia.org/wiki/Laser_cutting http://www.youtube.com/watch?v=M3zQKQ_sQRY http://www.youtube.com/watch?v=M3zQKQ_sQRY&feature=player_embedded http://www.youtube.com/watch?v=UeVEqrgC61Y&feature=player_embedded http://www.youtube.com/watch?v=a4gg9gm1DBs&feature=player_embedded
Psaroudakis, Nikolaos - 3D printing (stereolithography)Presentation: PDF Stereolithography, also known as 3-D layering or 3-D printing, allows you to create solid, plastic, three-dimensional (3-D) objects from CAD drawings in a matter of hours. This machine has four important parts: * A tank filled with several gallons of liquid photopolymer. The photopolymer is a clear, liquid plastic.
* A perforated platform immersed in the tank. The platform can move up and down in the tank as the printing process proceeds.
* An ultraviolet laser
* A computer that drives the laser and the platform
The photopolymer is sensitive to ultraviolet light, so when the laser touches the photopolymer, the polymer hardens.  The Stereolithography Process The basic printing process goes like this: * You create a 3-D model of your object in a CAD program.
* A piece of software chops your CAD model up into thin layers -- typically five to 10 layers/millimeter
* The 3-D printer's laser "paints" one of the layers, exposing the liquid plastic in the tank and hardening it
* The platform drops down into the tank a fraction of a millimeter and the laser paints the next layer
* This process repeats, layer by layer, until your model is complete
This is not a particularly quick process. Depending on the size and number of objects being created, the laser might take a minute or two for each layer. A typical run might take six to 12 hours. Runs over several days are possible for large objects. Once the run is complete, you rinse the objects with a solvent and then "bake" them in an ultraviolet oven that thoroughly cures the plastic. Stereolithography file format STL is a file format native to the stereolithography CAD software created by 3D Systems. This file format is supported by many other software packages; it is widely used for rapid prototyping and computer-aided manufacturing. STL files describe only the surface geometry of a three dimensional object without any representation of color, texture or other common CAD model attributes. The STL format specifies both ASCII and binary representations. Binary files are more common, since they are more compact. An STL file describes a raw unstructured triangulated surface by the unit normal and vertices (ordered by the right-hand rule) of the triangles using a three-dimensional Cartesian coordinate system. Examples    Stereolithography providers 1. Artcorp [http://www.artcorp.com/stereolithography.html] 2. Protocad[http://protocad.com/stereolithography.html] 3. Quickparts [http://www.quickparts.com/] 4. Protocam [http://www.protocam.com/] Pricing According to protocam, Stereolithography parts are priced using 5 criteria (in order of importance): 1. Overall height of the part - Most parts are built using a .004” layer thickness. The exception is a high resolution build which uses .002” layer thickness. The 3D file is “sliced” into layers and then traced and solidified layer by layer on the SLA machine. Consequently, a 6 inch part (1500 layers) will take longer to build than a 3 inch part (750 layers) and therefore, cost more. 2. Volume of the part - This relates to the number of cubic inches of material that will be needed to make the part. Again, the larger the part the greater the volume of material needed and the greater the cost. 3. Complexity of the part - When the part is finished on the SLA machine, it will require time to have the excess resin removed as well as having the support material removed. The prototype is then post cured in a UV oven and bead blasted to provide a consistent finish over the entire part. 4. Finish level of the part - ProtoCAM offers several levels of part finishing ranging from an economy “strip and ship” to a “presentation” level. Our standard level of finish requires the removal of supports with some light sanding on the support surfaces with an overall bead blast prior to shipping. 5. Lead time of the part - ProtoCAM’s standard lead time is 2 days after receipt of order. Some parts, due to size, require a longer lead time. If you need your prototype part sooner, there is an additional charge to accomplish that requirement.
Waxman, Noah - 3D printing - Fused deposition
HERE IS MY PRESENTATION: http://blog.noahwaxman.info/?tag=fused-deposition Indiana, Scott Wayne - Cutter plotter - Vinyl cutter
 A vinyl sign cutter (sometimes known as a cutting plotter) is used by professional poster and billboard sign-making businesses to produce weather-resistant signs, posters, and billboards using self-colored adhesive-backed vinyl film that has a removable paper backing material. The vinyl can also be applied to car bodies and windows for large, bright company advertising and to sailboat transoms. A similar process is used to cut tinted vinyl for automotive windows. Colors available are generally limited only by the collection of vinyl on hand. To prevent creasing of the material, it is stored in rolls. Typical vinyl roll sizes are 24-inch, 36-inch and 48-inch width. Generally the hardware is identical to a traditional plotter except that the ink pen is replaced by a very sharp knife that is use to cut out each shape, and the plotter may have a pressure control to adjust how hard the knife presses down into the vinyl film, allowing designs to be fully or partly cut out. The vinyl knife is usually shaped like a plotter pen and is mounted on ball-bearings so that the knife edge rotates to face the correct direction as the plotter head moves. Sign cutters are primarily used to produce single-color line art. Multiple colors can be cut and assembled but the assembly process is extremely painstaking if the cut sections are thin and flexible. As with the pen plotter, sign cutting plotters are in decline for general billboard and sign design. They are being replaced by wide-format inkjet printers that use special fade-resistant UV-protected solvent-based inks, which can directly print onto fabrics, vinyls, or plastic sheeting. These large inkjet printers have the added advantage of performing smooth color transitions and photo printing, which sign cutters cannot duplicate. However, sign cutting plotters are still very much in use for precision cutting of graphics produced by wide-format inkjet printers, for example to produce shaped stickers and window graphics.   Some personal vinyl cutters: *http://www.printeresting.org/tag/personal-vinyl-cutter/ Zaks, Shahar - CNC knife - corrugated cardboard cutter
Felisia Tandiono - Link to blog about DIY rapid prototyping
Slava Balasanov - EDM- Electrical discharge machining
types of EDM machines: Wire EDM - a wire is fed continuously into the machine held together by two diamond guides move in x y plane usually uses water as its dielectric fluid  Sinker EDM - like cnc  usually uses oil as its dielectric fluid How EDM works: Sinker IDM: http://www.youtube.com/watch?v=4doVz_a2yvs&feature=related DIY EDM!!! places close to nyc: OTHER LINKS3d Printed Textiles
3D Gold printing 3D Titanium Printing  |
