Prepare for manufacturing basics

In this Design for Manufacturing course by Andrew Camardela, you’ll turn an existing lamp design into a manufacturable model. Pinpoint key adjustments to improve manufacturability, considering a variety of low-volume production techniques. This course focuses primarily on sketch and solid modeling basics while exploring a variety of tools and features, including Shapr3D’s adaptive user interface and history-based parametric modeling.

 

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Welcome to a Shapr3D Design for Manufacturing Course by Andrew Camardela

Follow along with Andrew Camardela, Industrial Designer Consultant and Faculty Member at DePaul University, as he shows you how to turn an existing lamp design into a manufacturable model. You’ll create all the templates, dies, and tools to fabricate the components out of real materials, preparing the lamp model for production.

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Design for Manufacturing Modeling Basics | Shapr3D Design for Manufacturing

Start off exploring how to make initial adjustments to each model component to improve manufacturability, leveraging Shapr3D’s design history. You get introduced to Shapr3D’s adaptive user interface and adaptive parametric modeling while going through various options for tools to tackle adjustments.

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Adjusting components | Shapr3D Design for Manufacturing

Start off exploring how to make initial adjustments to each model component to improve manufacturability, leveraging Shapr3D’s design history. You get introduced to Shapr3D’s adaptive user interface and adaptive parametric modeling while going through various options for tools to tackle adjustments.

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Dies and tools for fabricating base plate | Shapr3D Design for Manufacturing

To make a die for a base plate, you’ll form a block around the base plate and use the Subtract tool to create a pocket inside of the block. Adjust design history to reorder steps and adjust additional target bodies.

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Transfer punch die for lamp base plate | Shapr3D Design for Manufacturing

Continue making a template that acts as a jig to hold a transfer punch for the lamp base plate. You’ll walk through projecting the base plate onto the surface of a block to trim and cut from a duplicate die and form the jig using tools like subtract and chamfer.

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Lamp base cover die | Shapr3D Design for Manufacturing

Make a single die holding four welded pieces together to construct the lamp base cover. After projecting sketches onto your sketch plane, you’ll extrude the template, making space for clamps and including reliefs to prevent welding damage to the overall template.

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Clamp and router template features | Shapr3D Design for Manufacturing

To finalize the lamp base tool, you’ll extrude bottom and side clamp holes as well as define the top surface area for the router to follow. This includes offsetting the base profile, constructing the clamp area, extruding, and mirroring to create bottom clamp holes, followed by creating a box around the top of the base to then extrude away.

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Construct arm base fixture | Shapr3D Design for Manufacturing

Make a fixture that fits directly around the base of the arm part. You’ll use sketch planes and extrude to build a box with spaces for drill holes on the bottom.

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Template to define arm base shape | Shapr3D Design for Manufacturing

Utilize the box you built as a template around the arm base to define the curvature and slope as well as cut and extrude holes. You’ll project linework onto the bottom and side sketch planes, cutting the overall curvature and slope of the base, and extruding cavities to further define the shape to prepare for router use.

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Template to round arm base corners | Shapr3D Design for Manufacturing

Complete the template for the lamp arm base to include the round corners. To do that, you’ll work between design history and directly editing geometry, projecting the top face onto the bottom surface, and extruding up to create enough room for the router to make the cut.

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Lampshade positive mold | Shapr3D Design for Manufacturing

Manufacturing the shade leaf of the lamp shade will take two different tools. Learn how to make the first one, a positive mold where the plastic gets molded to the outside of it, directly editing the part, extruding, and subtracting the shade leaf to create the part.

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Lampshade outer tool surface guide | Shapr3D Design for Manufacturing

Start constructing the outer tool to trim the vacuum-formed part by sketching a surface guide on of flat faces on top of half of the shade to mirror later on. You’ll use a cross-section of the lampshade leaf and project onto a parallel plane to sketch out features for the tool. This will create flat faces to use to trim away the inner surface of the component.

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Lampshade outer tool main body | Shapr3D Design for Manufacturing

Make the main body for the tool by creating a solid that can get cut away and guide a router around the part. You’ll split the lampshade in half to mirror later on. Then follow along with directions on creating a sketch, projecting an entity onto the surface of the sketch, extruding, and subtracting on all the outer faces of the lamp shade to remove extra material and create a travel for the router to follow.

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Complete the lampshade outer tool | Shapr3D Design for Manufacturing

Complete the outer tool body by cutting out where the hole for the lamp shade leaf and subtracting the inner surface. You’ll use a combination of the subtract tool to create the subtracted body and match outer curvature, revolve extrude to create a relief area, and mirror and union to create complete component. This gives the location of the hole and the track for the router to trim the component all the way around.

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Main tool for inner arm | Shapr3D Design for Manufacturing

Create the main tool for the inner arm in the same c-shape to wrap laminated wood around, with extra space provided to clamp the pieces together. Walk through how to construct the framework and extrude to build the basis of the tool.

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Interior template clamp holes | Shapr3D Design for Manufacturing

Get step-by-step instructions for creating clamp holes by adjusting the design history breakpoint and working with the pattern tool to create an array of holes along the main tool.

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Lamp arm exterior template | Shapr3D Design for Manufacturing

Make a template to carve out the outside shape of the lamp. You’ll extend the interior template sketch framework using parallel construction lines and offsetting them to create a basis for the outer template. Customize the offset to fit your router bit’s bearing lines and length.

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Template for trimming inner pockets and groove | Shapr3D Design for Manufacturing

Cut out a guide in the exterior template to create the groove and hole details in the lamp arm and trim the outer edges including cavities. You’ll build a construction axis, extruding the grooves and holes while excluding bodies in design history, and using subtract and union to create the framework for clamping pieces together and trimming the outer body surface.

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Trimming tool for upper part of lamp | Shapr3D Design for Manufacturing

Create a trimming tool for the upper part of the lamp, including hole details. You’ll build a feature that keys into the arm c-shape with a flat surface at the bottom to fit appropriate machinery, like a drill press.

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Trimming tool for lower part of lamp | Shapr3D Design for Manufacturing

Build a similar trimming tool for the lower part of the lamp, keying into the arm shape and filleting the final shape to provide a complete track for the router along and extruding holes for drilling. You get a foundational part that you can customize to include additional features for keying, clamping, or fixturing.

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Installing lamp post and base | Shapr3D Design for Manufacturing

Walk through adding the final touches to the arm, installing the fabricated lamp post and the bottom base to the arm. You create a feature to key the bottom base to the arm, working with design history as you extrude and fit the base tool to the shape of the arm.

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