Principles of Engineering

Unit 2.1 Manufacturing & Materials

Tic-Tac-Toe Game Project Design Brief Client: Wilson School District Target Consumer: I-STEM Students Problem Statement: Create a project that provides students with hands-on insights and experiences related to material science and manufacturing processes to better understand how everyday items are designed and produced. Design Statement: Design and mass produce a simple game that serves to teach students about various design and manufacturing methods as well as material properties through active participation in the entire process. Constraints:

• Must utilize of variety of materials - metal, organic, polymer, ceramic, composite • Must use a variety of manufacturing methods and processes • Must incorporate traditional and newer manufacturing methods • Must utilize available materials, machines and equipment • Must be able to be created/manufactured "in-house" • Meets all health and safety regulations • Needs to be low in cost to produce (<$3.00 each)

Criteria:

• Must be a working, functional game and easy to use/assemble • Allows students to identify materials and their properties • Promotes knowledge of manufacturing processes/methods • Provides students with experience using technology • Must be able to be easily connected to the learning goals of the instructional unit • Students must demonstrate the knowledge and application of all general lab safety

rules and specific safety considerations and rules for the use of lab tools, machines and equipment.

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Project Overview

Design Drawings: (1) 3D board design in Autodesk Inventor (1) 2D board grid lines in Adobe Illustrator (1) 3D "X" part design in Autodesk Inventor (1) 3D "O" part design in Autodesk Inventor (1) 2D "X" design in Adobe Illustrator (1) 2D "O" design in Adobe Illustrator Parts: Each Tic-Tac-Toe game will consist of the following parts: (1) Tic-tac-toe board w/ lasered lines made from wood and composite material (2 each)

Processes Used: CNC routing, laser engraving, 3D printing, injection molding, casting, drilling, parting, knurling, finishing Materials Used: Wood, acrylic, polymers (acrylic, acetyl, polyethylene), pewter, brass, aluminum, steel, ceramic Four (4) Person Student Group: 1. Each student in the group must complete all the design drawings listed above 2. Each part(s) must be drawn using the appropriate software program (Inventor or Illustrator) 3. Parts must be designed to the exact dimensions specified 4. Each group will create a minimum of 4 copies of each part to create 4 game sets 5. Groups will rotate through different processes and machines as directed by instructor General Safety Rules and Notes: 1. Safety glasses are required and must be worn at all times when in the lab. 2. Long hair must be tied back and secured at all times when in lab. 3. Loose clothing must be tucked in and secured. No open toe shoes or sandals permitted! 4. Jewelry that could interfere with the safe operation of tools/equipment must be removed. 5. Students may NOT use tools, machines or equipment if they have not received teacher training and demonstration before use. 6. Report any injuries, no matter how minor, to your teacher!

kjjkk (1) "O" made from wood/acrylic/acetyl (1) "O" made from polymer casting (1) "O" made from brass w/ knurled finish (1) "O" made from aluminum (1) "O" made from 3D printing

(1) "X" made from wood (1) "X" made from acrylic (1) "X" made from ceramic (1) "X" made from injection molding (1) "X" made from pewter casting

The Board: Design Information

3D Board Design: 1. Open Inventor and create a new part file (.ipt). Create a new 2D sketch 2. Using the X,Y coordinate plane, draw and dimension a 3-1/2" square from the 0, 0 position. 3. Finish sketch, select 3D model tab 4. Select and extrude the square to a depth of 3/4" 5. Create new sketch (right click on board front face, select "new sketch" 6. Draw a 7/8" diameter circle in the upper left corner & set dimensions as shown in diagram 7. Finish sketch, select 3D model tab 8. Select and extrude the circle inward to a depth of 1/4" 9. Use rectangular array feature to copy and paste eight (8) more 7/8" diameter circles with proper spacing (holes should be evenly spaced as shown in diagram)

Board Dimensions: Note: Hole diameter is 7/8", hole depth is 1/4". Board dimensions are 3-1/2" x 3-1/2" x 3/4".

The Board: Design Information 2D Board Design: 1. Open Adobe Illustrator and create a new file 2. Set document dimensions to 3-1/2" x 3-1/2" 3. Select the line tool, set the fill to none and the stroke weight to 1-3 pts 4. Create (4) 3-1/4" long tic-tac-toe grid lines (2 vertical and 2 horizontal) with proper spacing and position as shown in diagram below. Hold the Shift key down while you create your lines to ensure a pure vertical or horizontal line. 5. Use the X,Y coordinates to position lines precisely (see below) 6. Save your file

Use the X and Y boxes and the height (H) field to create your lines to exact specifications

The Board: Material & Production Information

Per Four (4) Student Group Materials: (1) 3/4" x 3-1/2" wood stock (1) 3/4" x 3-1/2" composite stock Steps: 1. Cut wood and composite stock into 3-1/2” squares using appropriate hand tools and machines 2. Two (2) boards will be created using the CNC router (see instructions) 3. Two (2) boards will be created using drilling processes (see instructions) 4. All boards will have grid lines laser-engraved on the board surface (at a later time) Process 1: board designed in Inventor and machine code is written for CNC router Notes: Process 2: board designed in Inventor, and machined using drill press and jigs Notes:

The Part: 3D Design Information

3D "O" Design: 1. Open Inventor and create a new part file (.ipt). Create a new 2D sketch 2. Using the X,Y coordinate plane, draw and dimension a 3/4" diameter circle 3. Sketch a second circle from the same center point at 1/4" diameter 4. Dimension the sketch 5. Finish sketch, select 3D model tab and the extrude tool 6. Select circle surfaces and extrude to 1/4" depth (inward direction) 7. Save file in 2 formats – as an Inventor file (.ipt) AND an .STL file

Notes:

The Part: 2D Design Information

2D "O" Design: 1. Open Adobe Illustrator and create a new file with document dimensions of 1-7/8" x 1-7/8" (see below) 2. Turn on grid and snap features (in "View" drop down) 3. Select the ellipse tool and set stroke weight to .001 inches. 4. Draw a "O" shape using the ellipse tool following the dimensions provided (.75 inches). 5. Draw the center O circle using the ellipse tool following the dimensions provided (.25 inches). 6. Lasso your completed O shape and confirm the stroke weight is set to .001 inches 7. Copy your "O" shape (both inside and outside circles) and paste to create 4 "O" shapes as shown below. Save your file.

Ellipse tool

Set stroke weight

Set outer circle dimension to .75"

Set inner circle dimension to .25"

Notes:

The Part: Material & Production Information Per Four (4) Student Group Materials: (1) 3/4" x 4" acetyl/acrylic/wood bar stock (your choice) (1) Polymer casted (1) 3/4" x 6" or longer aluminum bar round stock (1) 3/4" x 6" or longer brass bar round stock (1) 3D print Steps: 1. Select and cut stock to size specified above using appropriate hand tools and machines 2. Separate metal materials from acrylic/wood materials 3. Produce parts using appropriate hand tools and machines as instructed and demonstrated 4. Produce a total of (20) "O's", four (4) from each of the five materials specified. Processes: Acrylic/Acetyl/Wood: table saw, band saw, miter saw, drill press & hand tools Notes: Follow demonstrated processes Processes: Metal Stock: band saw, metal lathe, knurling tool and hand tools - one metal sample must include knurled surface finish. Notes: Follow demonstrated processes

Processes: Polymer Casting: mold, polyurethane parts A & B Notes: Follow demonstrated processes Processes: 3D Print: 3D printer and material Notes: Follow demonstrated processes

The Part: 3D Design Information

3D "X" Design: 1. Open Inventor and create a new part file (.ipt). Create a new 2D sketch 2. Select the X,Y coordinate plane, draw and dimension a 3/4" x 1/4" rectangle 3. Draw a second rectangle with the same dimensions as step 2 but perpendicular to the first rectangle (see diagram below) 4. Dimension the sketch to match model shown below 5. Finish sketch, then select 3D model tab 6. Select the extrude tool and extrude both rectangles to a 1/4" depth to form a 3D "+" shape. 7. Save file in 2 formats – as an Inventor file (.ipt) AND an .STL file

Notes:

The Part: 2D Design Information

2D "X" Design: 1. Open Adobe Illustrator and create a new file with document dimensions of 1-7/8" x 1-7/8" (see below) 2. Turn on grid and snap features (in "View" drop down) 3. Select the line tool and set stroke weight to .001 inches. 4. Draw a "+" shape using the line tool following the dimensions provided. All line segments should be 1/4" long 5. Lasso your completed + shape and confirm the stroke weight is set to .001 inches 6. Copy your "+" shape and paste to create 4 "+" shapes exactly as shown below. Save your file Draw single "+" shape - all line segments are 1/4" long. Overall length/height = 3/4"

Copy and paste to create 4 shapes, spaced as shown

line tool

Set stroke weight

The Part: Materials & Production Information Per Four (4) Student Group Materials: (1) 1/4" x 1-7/8" x 1-7/8" acrylic flat stock (1) 1/4" x 1-7/8" x 1-7/8" wood flat stock (1) ounce plastic injection material (polypropylene) (1) ounce 3D printing (ABS plastic) (1) ounce pewter casting metal Steps: 1. Select and cut wood and acrylic stock to size specified above. using appropriate hand tools and machines. 2. Produce parts using appropriate hand tools and machines as instructed and demonstrated. 3. Produce a total of 20 "X's": (4) acrylic, (4) wood, (4) ceramic, (4) pewter, (4) injection molded. Processes: Acrylics and Woods: laser engraver - follow demonstrated process Notes: Processes: Metal – Pewter Casting: - follow demonstrated process Notes:

Processes: Polymers: injection molding - follow demonstrated process Notes:

Processes: Ceramic: slip-casting, glazing and firing - follow demonstrated process Notes:

POE Unit 2.2 & 2.3: Tic-Tac-Toe Game – Task Checklist

Note: All class/lab/equipment safety tests must be completed with 100% accuracy before beginning. Also, you must have your instructor check your machine/process set-up before proceeding with any of the steps below! Drawings □ 3D board design (Inventor) □ 2D board engraved lines design (Illustrator) □ 3D “O” design (Inventor) □ 2D “O” design (Illustrator) □ 3D “X” design (Inventor) □ 2D “X” design (Illustrator) Wood & Acrylic “X’s” □ cut acrylic for “X” parts to size per instructions □ make/use a jig/fixture that will properly place your work piece for engraving □ laser engrave “X” parts from Illustrator file (check settings!) Injection Molded “X’s” □ produce 4 “X” parts - injection molding process Pewter Casted “X’s” □ produce 4 “X” parts - pewter casting process Ceramic “X’s” □ create mold template in Illustrator □ create mold original (laser engraver) □ create/use 1-2 piece mold □ slip cast O pieces □ fire kiln-dried clay at recommended temp./time □ glaze and fire according to recommendations. Polymer Casted “O’s” □ Use/create silicone mold □ Prepare mold (heat, talc powder) □ Pour, prepare and mix A & B material □ Allow material to harden and de-mold Complete Spreadsheet: POE Unit 2.2.2 & 2.2.3 – Materials, Manufacturing Processes and Recycling

Complete Conclusions found at link below: POE Unit 2.2 Conclusion Questions

Period: _____ Group #: ______

Name: _____________________________________ Name: ______________________________________

Name: _____________________________________ Name: ______________________________________

Game Boards □ cut wood for boards to size □ layout hole locations □ use drill press to make 2 boards □ use CNC router to make 2 boards □ plan/use fixture for engraving board lines □ laser engrave game board lines on finished boards 3D Printed “O’s” □ produce 4 “X” parts - 3D printing process Wood/Acrylic/Acetyl “O’s” □ cut material to length (4”) for “O” parts □ drill +/- ¼” center hole for wood “O” parts □ cut drilled “O” parts into individual pieces (1/4” thick)

Aluminum & Brass Metal “O’s” □ drill +/- ¼” hole in center of round bar stock on metal lathe (may need to start with smaller hole size and work up to ¼” size, especially if using steel/stainless steel) □ select one (1) metal type only (brass) and create a knurled finish with knurling tool □ cut drilled metal “O” stock into individual pieces (1/4” thick)