The goal of this project is to apply all that we've learned this semester to work in a team of 4 and create a 2.5+ degree of freedom machine.  We decided to create the Foaminator, a 3 axis CNC mill. This project is constrained to use only 3D printed parts, thus, we specify our machine to be used for cutting foam, though other materials are possible, so long as cutting loads are kept low. 

My contributions included integrating all the electronics, figuring out the controls and creating gcode for demonstrating the machine, and designing the X gantry, spindle holder and Z axis drive. 

Our main goal with this project is to create an extremely simple machine that just works. Simple parts that can easily be 3D printed, simple controls that can easily be operated and debugged, and a simple machine that can easily be assembled, modified and upgraded. We accomplished this with a hybrid gantry/bed slinger design. The X and Y are belt driven and the spindle rides on a lead screw.  Additionally, we only used 5 unique 3D printed parts in the entire machine. 

For controls, we used a makerbase running the opensource Marlin firmware, Gibbscam to generate gcode, and Repetier-Host to communicate with the makerbase.  In the interest of time and avoiding scope creep, we decided to post process the gcode manually, instead of writing our own post processor. For simple demos this is okay, but this is something I'd want to address in the future.

By proofing our design on a a small scale, we open the door to a future, larger machine, that can help cut larger parts, for example foam plugs used to create negative molds for FSAE parts, such as nosecones and other aerodynamic devices. 

Overall this project was a success. We delivered a fully operation, 3 axis CNC mill by the deadline.

Skills: CAD, Machine Control, CNC Mill, 3D printing

The goal of the gasket project is to take a part and create a gasket that matches the geometry of the given part.

I started with the part, a unique aluminum block, and took measurements of the block and all of its features, all within 0.005" of the nominal values. While measuring, I sketched the gasket and its features, along with the relevant positional and nominal geometric dimensions. Using this sketch I created a CAD model of the gasket. I then used Gibbscam, a CAM software, to create toolpaths that would cut a piece of stock material into the desired gasket geometry. Once doing so, Gibbscam generated machine friendly code that I loaded up into the CNC mill, and cut my gasket.

As seen in the photos below, the gasket fits great. If I were to make this again, I would fix an inefficiency in the CAM, which tells the machine to make unnecessary vertical travels between each holing operation, in order to save time while machining. 

Skills: CAD/CAM, CNC Mill, metrology

The goal of the phone stand project was to ideate, sketch, model and 3D print a phone stand that lets you prop up your phone for watching videos, movies, etc. The only constraint is to keep the stand within a 2x2x2in envelope.

In my mind, the best way to view a video on your phone is in landscape mode, so that is the orientation I considered for this project. I started by sketching a rough design. I wanted it as simple as possible, so I just made a triangular shape that elevated the phone to a comfortable viewing angle, and added a lip so phones wouldn't slip out. 

I put the design into CAD, ensuring it fit within the envelope, and then set arbitrary dimensions to non critical features. I also modeled my phone, assigned materials to the parts, and used the mass properties tool in my the CAD software to visualize the center of gravity, ensuring the phone stand wouldn't topple over.

I 3D printed the phone stand using an FDM printer, and finally had my part. The phones fits in easily and doesn't topple over, so this project was a success.

Skills: CAD, 3D Printing