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Week 18 - Wild card week

Individual assignment: Design and produce something with a digital fabrication process (incorporating computer-aided design and manufacturing) not covered in another assignment, documenting the requirements that your assignment meets, and including everything necessary to reproduce it. Possibilities include (but are not limited to) composites, textiles, biotechnology, robotics, folding, and cooking.

This week i thought i will try composite materials for the wildcard, since i haven't done the same earlier in any of the weeks

Composite material

A composite material (also called a composition material or shortened to composite, which is the common name) is a material made from two or more constituent materials with significantly different physical or chemical properties that, when combined, produce a material with characteristics different from the individual components. The individual components remain separate and distinct within the finished structure, differentiating composites from mixtures and solid solutions

My plan was to make a small boat with polystrene as one of the material. I had designed a ship with small dimensions in fusion. My inspiration was the toy steam boat which i get from local shops

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I even tried to make coil for the steam boat using flexible pcb in the lab and tried to heat it after filling water, but it was a failure

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Designing different layers in fusion

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Design concept of the game

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A shape of the required boat was created

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Two mould were made in the shape giving a gap between them to fill the resin

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In order to manufacture the same in shopbot ,two components were created and are exported to another seperate drawing files. Files can be downloaded from here1 here2

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Add tool, i had chosen ball end mill in fablab since i am using thermocol of 100mm thickness. The required dimensions were added in tool library

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Create tool paths

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2D & 3D tool paths were created as per the requirement as shown below

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After that gcode for shopbot .sbp file was created from 'post process' option as below

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Operating shopbot using the generated gcodes

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Five layers of fabric was made to cover the bottom mould by cutting the shape manually

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The fabric was poured with resin in the ratio of 500gm:250gm. Top and bottom mould was pressed between them

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Most of the thermocol was removed using different tools, and to finish the same acetone was used

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Boat after removing the thermocol

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DESIGN FILES FOR DOWNLOAD

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Week 14

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Week 16

17

Week 17