CAD/CAM Manufacturing

PURPOSE: This course introduces students to the materials and processes of industrial mass production and will focus upon student-directed research and development. Students will design and build products that are solutions to problems. Students will be involved in advertising, marketing research and sales appropriate to a small manufacturing business.

COURSE OBJECTIVES: After successful completion of this course you will have a better understanding of designing and development of products for production. Along with the design and manufacturing we will cover the following consumer components: economic principles, responsible consumers, and money management. We will have a communication unit that will be geared toward advertising, marketing, and presenting ideas and products.

COURSE OUTLINE: Throughout the course of the semester we will design and build products within the constraints of the design loop. Each unit will build knowledge and skills to prepare for a final project that will assess students ability to design, manufacture, and market products.

The Design Process The design process is a way of organizing all of the issues and information that must be considered to allow a design team to work together professionally.

PROBLEM Definition
"Determine the need then convert the need to a problem. Define the problem. Next make sure you understand the Problem.

State the Problem
Enter the creative problem-solving cycle with a statement of a problem that pertains to a specific topic. This is a statement describing what the solution to the problem should do and what constraints are being imposed.
· An open-ended question
· An existing condition in need of change
· A kit of materials provided to design and build something

Once you Define the Problem…..

Let Go
The more innovative designers in this world have a secret. Their secret is they don't worry about looking foolish! When they ask, "What If," and follow that with free flowing ideas, not bothering with trying to make sense of it, or its logic. If you are working within a group, it is rare--if ever-- to find a group coming up with new ideas. At best groups stimulate and help define the problem, and get innovative people thinking; and at it's worst, it strong-arms thinking and the chosen approach is--what groups do--a compromise. Compromise, is not a bad word, that is, in fact, what Engineering is; but it has no place in the Innovative Process.

Try Several Approaches
It's important to think of several ways of doing the same "thing." Beware of "falling-in-love" with any single approach too early: it is the kiss-of-death; it's like a tune you can't get out of your head: you cannot think of another way of doing...

Do a Paper Design On Each
A paper design can be anything from gestures (quick 15-second sketches) to a CAD layout to formal flowcharts. However you do it, Do It! The quicker you can get several different views spread out in front of you, the better. Remember: Form does not replace function.

Information Gathering
Before attempting to develop solutions, the designer must become familiar with the influencing factors associated with the problem. NOW! You can start to use "Cook Books." Now that you have some handle on what it is you are "About," the way others have attacked the same kind of problems will be less apt to prejudice you. Things you should consider at this time:
· What attempts have others made to solve this problem?
· What is the size, stresses, loads, power requirements?
· Appearance and ergonomic factors involved?
· Brainstorm list of possible solutions to the problem
· Functions-what must the product do?
· What materials will be used to make the product?
· How will the product be put together?
· How much will it cost to make?
· How much will the consumer pay for the product?
· What are the safety issues?

Evaluate YOUR Designs
Evaluating your approach(s) against others, is a kind of check on your powers of observation, analysis and synthesis--Design. This is a great way to compare and do a reality check.

Modify Designs
In comparing the several ways of doing something, several things happen, the problem may become clearer to you and your ready to fine tune your design. Or you need to go back to square one, and do it again. NOBODY is PERFECT! Making mistakes is part of sharpening your skills.

Rank Each Design
You might use a matrix or chart to quantitatively compare each.

Example (Scoring 5 = high, 1 = low)

Specification	Weight	Concept 1		Concept 2		Concept 3
		Score	Wt. Score	Score	Wt. Score	Score	Wt. Score
Cost to produce	4	5	20	5	20	3	12
Size	5	2	10	3	15	3	15
Durability	4	4	16	4	16	4	16
Assembly Time	3	5	15	4	12	3	9
Aesthetics	3	3	9	2	6	4	12
Total			70		69		67

Pick the Best Design
From the Rankings; GO with the Design that appears to have the most going for it.

Keep Remaining Designs Active
Don't throw away the remaining designs!
Often, after pursuing the chosen approach, flaws are revealed and the designer must go back to "square one."
Good designers have other approaches waiting in the wings, and they carry on with little lost time.
So periodically revisit and rethink all of your initial designs, using your recently gained insights on the problem at hand.
A word or two of Caution:
If you do decide to abandon an approach, don't do it until you have tried 'everything' and are convinced--on the evidence--that this way will not fly. Don't abandon it because you feel it won't work. --Know!

Keep an Engineering Notebook
Write everything down. Document! Document! Document!
So keep the notebook up to date and have it Witnessed often by those whom you trust, and understand your work. This can mean the difference between Owning the Patent Rights to your Work, or NOT! It can jog the memory and reduce the number of times you do the same tests.

Build Prototype(s)
This is the construction step of the process. Appearance is more important here, but only so far as the need to "sell" the idea or product. Debug & Test Prototype

Testing and Evaluation
The solution should always be evaluated against the requirements established in the design brief and against the original problem statement. Testing the solution to see if it handles the load, operates correctly, meets appearance requirements, is reliable and solves the problem is an important part of the design process. Evaluating the result should address the need for improvements, changes, etc.

Redesigning and Improving
This is where the evaluated and tested solution may be re-worked and re-tested. At this stage the appearance of the product takes on more importance.