Project Overview An introduction to 3D printing Designing 3D printing parts Redesigning the Clawbot 3D printing new Claw components Assembling & Testing 3D printed components Open 3D printing design challenge

LESSON 06

Lesson 06 - Starter 5" Wheel Delrin Bearing Flat Quick task: What are the following parts designed to do for a VEX robot? The claw Metal parts (various) 4.6mm Spacers 8-32 Screws Key words: Concept, design, solution, function, brief

Lesson 06 - Starter Things to identify… The Project Brief Learning objective: Identify criteria to successfully resolve a challenge or problem, develop creative solutions to problems that present a wide variety of issues, and apply knowledge and skill to creative designing and making. Things to identify… Today you are going to be set a design and make challenge. To be successful, you must employ the skills you have practiced in this project so far. The starting point is the project brief, in which the challenge is set out to you, but without the answers. Aesthetic needs Material needs The Project Brief Function needs Strength needs Size needs Support material needs STARTING POINT Key words: CAD, Library, heat processes, acrylic, MDF, profile, forming.

Open 3D Printing Design Challenges Solving a design challenge (choose) In this final lesson, you are challenged with designing, making, and implementing a built solution using your VEX Clawbot as the base structure for the robot. For each solution, you will need to develop a sketched design, draw it accurate (dimensionally correct), create it in CAD, manufacture using 3D printing, then fit and test the solution to your Clawbot robot. Choose a brief based on the level of challenge it presents Easy Design a modified claw to help in the sack attack challenge Easy Design a modified claw to pick up and stack 3 inch blocks Medium Develop a claw that can pick up and fire balls Medium Redesign the aesthetics of the clawbot into an identifiable design trend Hard Explore the design of gear systems to make the clawbot faster or more powerful Hard Redesign your clawbot to climb stairs

Open 3D Printing Design Challenges Get Designing… Based on the design brief you have chosen… Task Develop lots and lots of sketched solutions, either onto existing images of the clawbot, or just sketch free onto paper. Develop the sketching into more detailed ideas, either in 2D or 3D. Model the part in blue foam or in card to see to scale how it will look and feel on the robot. Plan how the part in 3D will sit on the 3D print bed, what support it might need, and what design changes you could make to make it easier to print.

Open 3D Printing Design Challenges Get into CAD… Open up Autodesk Inventor and start modelling to scale… Task Turn your sketched/modelled idea into a CAD part in the virtual environment of Autodesk Inventor. Build around existing parts (like this wheel) so that you can check how it looks and fits, or simply model freely on the screen. A single shape pulled up to create a solid, or pulled into a solid to create a cut A single shape spun around an axis or edge to create a solid in the shapes path. A single shape normally a circle, drawn onto a flat surface and drawn into or through a solid. A curve applied to edges using a given radius. An angled cut applied along an edge. Letters applied as a sketch to a surface and then either cut into or extruded off from a surface. A wall thickness applied inside a shape but removing all other materials to create a shell. A pattern of shapes created by selecting a single feature on a surface, and multiplying it.

Open 3D Printing Design Challenges Moving from CAD file to physical part How to 3D print your Inventor part files Step one With the part finished, select the app button top left, and choose Export followed by CAD Format Step two From the pop up, choose the STL file type, ensuring you select millimetre as the Units under the Options button. Step three Import the STL file into the 3D printer software, ensuring it is set to the bed. Now initiate the printer and choose print…

Open 3D Printing Design Challenges Evaluate your 3D printed solution Against the following criteria, evaluate how well you made your solution Part name/sketch Issue it was designed to solve What was the outcome (good and bad) How could you improve this part next time? e.g. wheel guard To prevent sacks getting stuck around the wheels during the sack attack game The wheels were protected from sacks, but the guards were hard to fit Move the screw points to the opposite side of the guards so that they can be mounted externally

Lesson 06 - Plenary As a class, let us consider the following questions? A. What important place does the brief play in a design project? B. How do project briefs become more challenging to meet? C. Why are functional products more challenging to design than aesthetic products? D. How could a design create design ideas that can be interpreted into CAD and CAM easier?

Summary Today you have: Learning objective: Identify criteria to successfully resolve a challenge or problem, develop creative solutions to problems that present a wide variety of issues, and apply knowledge and skill to creative designing and making. Today you have: Identified the key foci for a project brief, and set targets to meet it Developed a clear design solution or solutions that will work for the brief Designed ideas that can be converted into CAD files and subsequent CAM parts