Tutorial series: Design for manufacturing
What you'll learn
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.
Transcript
00:01
Now what remains is trimming the fillets on this bottom part of the lamp and also boring out this hole here. So we're going to do very much the same thing in the side sketch that we were working on earlier. I am going to create a flat that is perpendicular to the hole that we need to bore. So I'm just going to select kind of an arbitrary line here.
00:31
I'm going to click on this outer edge here, and that's going to give us the ability to extrude the appropriate dye.
00:46
And I'm going to bring back one of the sketches we were working on earlier for the outer arm. And I'm going to use that as a way of getting our last line in here to be correct.
01:06
So I'm going to project this previous sketch edge into our current sketch. And that way we can use that to help us define this bottom edge being perpendicular to the hole that we need to bore. So I'm going to select these two edges and I'm going to make sure that they're perpendicular.
01:35
And I'm also going to make this edge parallel to this edge.
01:51
Okay, so now if we lay this flat edge along the drill table, we'll be able to drill a hole perfectly through in a perpendicular manner.
02:09
I'm going to make this a round number as well. That's going to help us with just keeping things organized. And the only remaining thing I have left here is to add an extra edge to cut this area. So I'm going to add an extra line into this sketch.
02:31
and just draw a line here.
02:40
and we're going to make sure that this is parallel.
02:46
Perfect. So we're going to now create the extrusions.
02:54
The router bit that we originally used trimmed the overall shape of the arm, but it didn't create this fillet here. So I need to create a feature that is behind this fillet so that it doesn't get in the way when our template here is used to cut this feature out. So I'm going to hide this arm.
03:12
And I'm just going to put a line here to help subdivide this little area.
03:31
And I'm just going to go between these two edges here. And I'm going to just make this vertical.
03:40
Perfect. We can just double check that that edge is behind our fillet area, which it is. So that looks pretty good right there.
03:51
And now I'm just going to do my extrude. And this extra little feature here is going to be used to engage the part and make sure that everything is nested correctly when we're routing.
04:08
And this top section here is going to help clamp everything down and guide the router bit to make this front edge. So I'm going to make an extrude. We're using 50 millimeters as our dimension. Just like that. And I'm going to bring back our inner arm section.
04:33
And I'm going to use that to make a boolean subtraction from this bottom die.
04:41
tracks.
04:44
Perfect.
04:50
If we hide the inner arm, we'll see that we have a cutout or how that matches up.
04:58
Now that all that's left is to make sure that we have the top feature here to be able to route out that part. So I'm going to bring back that arm. I'm going to select this and the surface. I'm going to do a split body just like that.
05:17
And I can delete this section here because we don't need it. And all that remains is to fillet this corner here to match up with the lamp.
05:30
That looks about right right there. So now the router is going to be able to run along this top surface here and cut this inner edge perfectly matching. And this tool will locate itself along the lamp using this feature here that already matches up with the piece that was cut from a previous die. The last thing that remains is to drill out a relief area for our drill bit to be able to cut out this hole.
05:58
So I'm going to come to this top surface up here and create a new sketch. And I'm just going to project this circle to that surface. And that way I can just take this area.
06:14
just do a subtract extrude through the entire part so that I can cut all the way through.
06:24
And now we have our borehole.
06:29
From here I can finish up these tools by doing our Mirror and Union as we've been doing before, since we've been working across the mid-plane.
06:39
So I'm going to select both of these sections here and do a union.
06:48
And I'm going to do the same thing on the bottom.
07:02
There we go.
07:09
So now these parts are complete and the router bit's going to be able to travel along and trim this part to its final dimensions and we'll be able to put this on a drill press and drill a hole through the body of the part correctly. The nice thing about having these models is that we can continue to upgrade and improve them and add additional features for keying or clamping or fixturing. The last remaining thing is to do a little bit of housekeeping. Because there's a bunch of dies for this particular
07:37
I'm going to come in here and start naming them. So I'm going to just give them some arbitrary names.
08:06
turn on these upper areas like that.
08:17
name.
08:39
And then this is our main body for forming.
Try it yourself
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About the instructor
Andrew Camardella is an Industrial Design Consultant and Faculty member at DePaul University, with a diverse background stemming from his passion for creation, tinkering, hacking, and experimentation. His expertise in the product development process and proficiency with various digital tools enable him to seamlessly translate concepts, 3D models, prototypes, and products between physical and digital realms, enabling clients to address user needs and tackle complex design and manufacturing challenges. His extensive design and fabrication experience spans multiple industries, including consumer and commercial products, large-scale art, digital imaging, packaging, environment design, green design, and instructional content development for a wide range of clients including tech startups, consumer goods companies, artists, and inventors.