10. Mechanical design, machine design
Hero Shot
Group assignment:
- design a machine that includes mechanism+actuation+automation+application
- build the mechanical parts and operate it manually
- document the group project and your individual contribution
The group assignment page can be found on the Energylab 2024 website here
it is also embedded directly in the webpage below.
Individual assignment
Document your personal contribution on the project.
- Introduction
During Week 10 of the Fab Academy, our group set out to design and build a 3-axis CNC machine inspired by the Beehive mechanism (Beehive Axes GitLab Repository). The project focused on modularity, affordability, and functionality, using 3D-printed components and square metal bars to construct the machine. My individual contributions were pivotal in the modeling and selection of the mechanical components for our CNC system.
- My Contribution
- Conceptual Design and Mechanism Selection
I researched and analyzed the Beehive mechanism to understand its strengths and adaptability for our CNC machine.
Collaborated with the team to select a 3-axis configuration that maximized precision while maintaining structural simplicity.
Proposed the use of square metal bars (25 mm) for their robustness and compatibility with 3D-printed parts. This ensured minimal deflection and enhanced the machine’s overall stability.
- 3D Modeling and Prototyping
Modeled critical components of the machine using CAD software (Fusion 360 and FreeCad, Autocad): Linear guides and their integration points with the frame.
Custom-designed brackets to securely attach the bars to the printed parts. Motor mounts and coupling mechanisms for the stepper motors.
Ensured all parts adhered to the modular design principle, allowing for future upgrades or replacements.
- Testing and Iterative Improvements
Conducted simulations and fit-checks of the 3D-printed parts to validate the design before assembly.
Adjusted tolerances for 3D-printed components to ensure a seamless fit with the 25 mm metal bars and avoid slippage. Played a key role in testing the linear motion system, fine-tuning the alignment of the axes, and reducing friction.
File
What went wrong/What went well
- Challenges and Learnings
Challenge: Aligning the axes precisely using printed parts and metal bars proved difficult initially.
Solution: Introduced shims and improved the design of the mounting brackets for better alignment.
Learning: Collaborative projects like this highlight the importance of iterative testing and communication to merge ideas into a functional prototype.
My contribution to the Week 10 project demonstrated my ability to integrate design and engineering principles into practical applications. The resulting CNC machine not only met our expectations but also provided valuable insights into leveraging the Beehive mechanism for low-cost and scalable fabrication.
The experience reinforced my skills in 3D modeling, mechanical design, and teamwork—skills that I am excited to continue building upon in future Fab Academy assignments.