RoboChargers 2022�CAD Class
Week 2 Engineering Concept:
Manufacturing Methods
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts
Types of Manufacturing Processes
Subtractive
Starts with a large piece of solid material and removes material until a finished part is achieved.
Additive
Starts with liquid or solid material (or a combination) and joins them to form a finished part.
Deformative
Starts with a liquid or solid material and forces it into the final shape of the part.
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts
Subtractive
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts
Subtractive (Subcategories)
Machining
Converts all material not used in the final part to (unusable) chips or dust.
Parting
Cuts a part out of a larger piece of material leaving potentially usable material behind. A narrow area along the cut line is converted to (unusable) chips or dust.
Dividing
Cuts a part out of a larger piece of material leaving potentially usable material behind. No material is lost along the cut line.
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts
Subtractive - Parting - Sawing
Cuts a piece of raw material in two
A single feature can require multiple cuts
Can be used to make angled cuts
Types of saws:
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts
Subtractive - 2D Parting
Very similar family of manufacturing methods
Used to cut flat parts out of sheets/plates of material
Types of 2D parting:
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts
Subtractive - Milling & Drilling
Distinct from parting
Removes material from a piece of material by a spinning cutting tool
Drilling - Cuts round holes by moving the cutting tool up and down
Milling - Cuts material by moving the cutting tool sideways
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts
Subtractive - Turning (Lathing)
Material is held and spun around an axis
Cutting tools are brought against the part to cut it as it spins
Typically holds tools in line with the axis for drilling and tapping
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts
Subtractive - Dividing - Punching (Stamping)
Breaks or shears a part out of a sheet with a shaped punch.
Works the same way a paper hole punch does.
Multiple punches can be combined in one tool to save time.
Ranges from hand-operated presses to CNC to reciprocating presses
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts
Additive
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts
Additive (Subcategories)
Fusion
Forms a larger final part by joining smaller solid pieces of material. Typically uses heat or chemicals.
Composite
Forms a final part by joining dissimilar materials together. Typically combines a liquid and a solid.
Chemical
Forms a final part by slowly adding material using a chemical or electrical process.
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts
Additive - Fusion - FDM (Fused Deposition Modeling)
Melted plastic is extruded through a nozzle and laid down in layers to form a part
Plastic usually comes in a roll of filament
Most common type of 3D printing
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts
Additive - Chemical - SLA (Stereolithography)
Cures special plastic resin using light
Laser scanning
Light processed by a projector mirror (DLP)
Light filtered through an LCD
Forms parts in layers by curing cross sections of the part
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts
Additive - Fusion - Welding
Forms a final part from two or more parts
Parts are joined by melting the material between the two parts and allowing it to cool
Common types of welding:
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts
Deformative
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts
Deformative (Subcategories)
Cold Forming
Mechanically forces a solid raw material into a final shape at room temperature.
Hot Forming
Mechanically forces a solid or semi-solid raw material into a final shape at elevated temperature.
Molding
Forces a liquid material into a final shape at room temperature or at elevated temperatures.
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts
Deformative - Cold Forming - Bending
Typically used on sheet metal parts cut by 2D parting methods
Bent using a “brake”
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts
Deformative - Hot Forming - Hot Rolling
Hot ingots or strips of metal are rolled between large cooled rollers
Typically broken into multiple stages to from the final shape
Used in the production of raw metal profiles and sheet
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts
Deformative - Hot Forming - Extrusion
Semi-solid heated aluminum is pressed through a mold with a shaped hole cut in it
Hollow shapes can be formed with special molds
Used to form raw aluminum shapes
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts
Deformative - Molding - Injection Molding
Plastic pellets are melted and injected into a mold under high pressure
The mold splits in half to release the part
Complex parts can be created with more complex molds with moving parts
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts
Deformative - Molding - Pour Molding
Molten material or uncured resin is poured into an open-topped mold to fill a cavity.
Molds can be:
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts
Questions?
FRC Team 3005 RoboChargers
2022 CAD Class: Week 2 Engineering Concepts