Design for manufacturing modeling basics

00:02

Welcome to a Shapr3D tutorial. We're going to be taking a look at this lamp design here, and we're going to be taking it from a concept that was provided by a designer and turning it into a manufacturable model and also generating all of the templates, dyes, and tools that are going to be needed in order to fabricate the components out of the real materials. So while we could look at this and say, well, we're just going to 3D print.

00:27

or we're going to CNC machine all of these individual components, we're going to focus on how do we make these pieces out of the real materials and generate fixturing that then could help inform something that would be in mass production. The other perspective that we're going to take is really looking at this model as a prototype. So it's how can we use simple tools like routers, saws, presses, and molds in order to make these components as if a prototype shop was designing them.

00:55

or a small production run might be happening where we would be able to create all of the components necessary. Early on, I was looking at this model and did a little bit of housekeeping, setting up some folders here that is gonna help us keep these parts organized as we work on them. And really there's two categories. There's a bunch of stock parts that we need to consider how they interface with the lamp. And then there's a bunch of custom parts here.

01:23

And those custom parts are things that we're going to focus on generating all of the tooling that we need. So I'm going to turn off our stock parts really quickly and talk a little bit about each of the custom parts that we have. So first off, we have these three leaves here that are represented here in the model. And those leaves are we're going to assume are vacuum formed. And they're going to need to be obviously made from a single sheet of material.

01:51

We're going to need to make a mold in order to form that plastic. And then we're going to also make some templates to help us cut those pieces out and to have them be accurate. Again, this is intended to be a repeatable process. So we can take the beta version here of Shapr3D and we can start to modify those molds. We can modify those templates using the parametric design features in Shapr3D. The next piece here, you're going to see this, uh, wooden

02:21

C shape and this arm is really formed from two pieces. There's an outer skin here that wraps around an inner surface. So this inner shape here is going to be, we're going to assume is going to be made like a laminated wooden component, very much like a skateboard might be made. And then there's a bunch of slots and holes that need to be cut into it in very precise locations in order for this to work. So we have our cable channel here that goes into the base.

02:51

and wraps around. And there's also this socket up here that interfaces with a stock part here that holds the bulb in the correct location. Looking a little bit closer at the base, you'll see that we have a base plate here. And this is kind of an interesting component because it is a formed sheet metal part. So we're going to make a very simple die to press those out and also machine all the holes that are in the base. So that way they all line up when we assemble this lamp.

03:22

So I'm going to hide this one.

03:26

And moving along, we have our base cover. This is another sort of tubular component, and we're going to make a die that helps us form and shape this. You know, in a production environment, this tube shape might be a stock component that gets cut into sections. We're gonna also assume that this is a weldment. So we're not gonna spend too much time dissecting how we get the main profile, but we will make dies and how to shape it and how to assemble it later.

04:01

Finally, we have our bass component. This is actually a wooden component that gets attached to the main arm here in order to help us combine all the pieces together. And this piece has a few things going on. One is that it obviously supports the bass, but it also has a button that it is held by a bracket. And that button has to poke through this surface here. So there's a few things that happen.

04:30

One is to accurately machine the section so that the button ends up in the right place. And then when we attach this base piece to this arm, we'll be able to get that in the right spot, so everything lines up. All in all, we're going to be looking at some sheep forming processes. We're going to be making some templates and molds in order to be able to vacuum form some parts and to bend some wood.

04:57

and we'll be able to form and cut all of these components and assemble them. Since we're going to be taking all of these components here and making manufacturable versions of them, I'm going to copy them over. So we're going to make a new folder, call it Fabricated Parts. Then I'm going to select all of the components here that I would like to copy. And I'm going to click the copy button and drag this over to the side a little bit.

05:24

I like to make this number a nice round number just in case I need to move things back and forth. So I'm going to change this to 200.

05:35

And then I'm going to click and drag all of these components into our fabricated folder. And I'm going to deselect everything and hide our custom parts. And we're going to focus on just working on these fabricated components, occasionally taking a look back and forth to see how things are working out.