Modules for ‘Non-Dualism in Design’
Modules of ‘Design for CP Manufacturing’.
Product Development
- Convergent sketch ideation
- Drawing in two-point perspective
- Using cure colour pens to add form to sketches
- Divergent modelling using CNC Router and laminated Foam Board
- Drawing in illustrator and exporting sketches to ugs platform/universal g-code sender
- Calibration of CNC mill
- Printing 2d drawings and laminating onto plywood to use as stencil for modelling
- Extrusion of model schematics into Fusion 360 and conversion to parametric forms
- Saving from illustrator into file
- Opening DXF in Fusion 360 and extruding out the model within physical model parameters
- Using chamfer and fillet tools to round off corners and create ovular forms
- Compartmentalisation of form, orientation for printing with supports and creation of male/female connectors.
- Slicing the model into sub-components with reference to slicing orientation
- Drawing sketches onto the model
- Extruding male connectors and cutting female connectors
- Slicing models to gcode for PLA print export. Inside wall thickness and infill. Layer height and bed levelling.
- Exporting to Cura and changing the normals to smooth form
- Calibrating the print in Cura and changing inside wall thickness and infill density
- Print supports and brimming
- Transition to PETG printing of components
- Choosing the right PETG materials
- Where to get them from
- Minimising waste through inevitable print failures and recycling the waste
- Testing of concept and continual improvement towards simplicity/complexity
- Filming the model’s performance using high-speed camera
- Analysing points of failure and improving the model in Fusion
- Production of prototype with hexadecimal colour wrapping
- Assigning materials to the model and rendering for visual approval
- How to extract a colour pallet from an abstract photograph and determine hexadecimal code.
Manufacturing Design
- Nomination of components to individual printers
- Nominating components to best printer bed size
- Creation of a printing schedule, component rotor and weekly yields
- Production of a print rotar using excel and deciding on hardware volumes
- Calibration of print in relation to material tolerance
- Choosing best printing speed (mm/s) and layer heights
- Post-processing and lacquering
- Removal of print supports, Dremmel off loose material, Coating parts with Hycote
- Creation of assembly stages
- Converting assembly stages into repeatable/teachable process
- Incorporation of production yields into P&L financial model, to create annual revenue
- Using production yields and operational costs to produce a financial model for the business in Excel
- Adherence to yellow-belt LEAN SIGMA
- Define, measure, analyse, improve, control
- Tendency towards complexity and continual improvement
- Minimising waste
- 5s and the visual workplace
