materials and fabrication
Monday, April 9, 12
what material and fab technique should i use?
Part Size
Resolution
Material Properties (Mechanical, Thermal, Reactive, etc)
Part Geometry
Production Scale
Environment
Hand vs. Machine Control
Aesthetics
Cost
Monday, April 9, 12
overview
• Materials
• Digital Fabrication Techniques
• Analog Fabrication Techniques
• Finishing Techniques
• Scalability
Monday, April 9, 12
materials
Monday, April 9, 12
material selection
Polymers (thermoplastic vs. thermoset)
Metals (several alloy properties)
Ceramics (firing)
High-Performance (gore-tex, kevlar etc)
Composites (carbon fiber, honey comb, fiber glass...)
Natural Materials (textiles, paper, leather, etc)
GSD Material Library
http://www.matweb.com/
https://www.inventables.com/
http://www.thistothat.com/
http://www.onlinemetals.com/aluminumguide.cfm
Monday, April 9, 12
Monday, April 9, 12
digital fabrication
Monday, April 9, 12
lasercutting
Monday, April 9, 12
lasercutting
2D
Limit on thickness
Angled cuts
Tool offset
Most materials (due to fumes, melting, reflection etc)
Monday, April 9, 12
snap fit
Monday, April 9, 12
bendable
Monday, April 9, 12
t slots
Monday, April 9, 12
t slots
Monday, April 9, 12
3d printing
Lots of different techniques with different properties
Resolution
Material properties
Cost
Aesthetics
http://i.materialise.com/
http://www.shapeways.com/
Amit Zoran and Peter Schmitt
Monday, April 9, 12
fused-deposition modeling (fdm)
Monday, April 9, 12
stereolithography (sla)
Monday, April 9, 12
selective laser sintering (sls)
Monday, April 9, 12
3d printing
Monday, April 9, 12
cnc milling
Monday, April 9, 12
milling
Monday, April 9, 12
cnc turning
Monday, April 9, 12
suppliers
http://www.mcmaster.com/
http://www.onlinemetals.com/
http://www.sdp-si.com/web/html/products.htm
http://www.aliexpress.com/wholesale/wholesale-alibaba-express.html
http://www.jfreeman.com/
http://www.lessemf.com/
Monday, April 9, 12
analog fabrication
Monday, April 9, 12
tapping
Monday, April 9, 12
counter sinking
Monday, April 9, 12
sheet forming (bending)
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Monday, April 9, 12
casting
Monday, April 9, 12
injection molding
Monday, April 9, 12
protomold
Monday, April 9, 12
protomold
Monday, April 9, 12
vacuum forming
Monday, April 9, 12
finishing
Monday, April 9, 12
abrasive blasting
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anodizing
Monday, April 9, 12
powder coating
Monday, April 9, 12
veneering
Monday, April 9, 12
scalability
Dependent on how material, fabrication technique, assembly and labor come together.
Laser, waterjet cutting, milling - small to medium scale (very dependent on set-up)
3D Printing - small scale (cost and time are high, but labor is low)
Casting - medium scale (fast, although labor can be intense)
Injection Molding - gazillion scale (cheap, fast, little labor)
Monday, April 9, 12
Monday, April 9, 12