Modeling & ManufacturingUsing Alpha_1

Samuel Drake

1984 -- Start of what became the AML

• Purchased 5-Axis Vertical Machining Center• First Manufactured Item – 3D surface for a

shaped charge• Second Demonstration Item – Injection mold

for a teaspoon that had been modeled by Beth Cobb. Made Plastic spoons with an Alpha_1 logo

Adding Capability to the AML

• 1989 Mill-Turn• 1991 Stereo Lithography Rapid Prototyping • 1992 Sinking EDM• 1994 5-Axis Horizontal Machining Center• 1995 Wire EDM• ?? Coordinate Measuring Machine• 2002 Move to High Bay in Kennecott• 2005 High Speed 5-Axis Machining Center

Moving into Kennecott

Major Machine Lineup in AML

Parts on Demand Systemand Bushing Maker

• ~1989 Started working with Hill AFB• Origins of what became FeatureCAM• Developed Bushing Maker Software with EGS• Live Demo in AML• Demo with EGS at Hill AFB

Early Work on FeatureCAM

• Prior work with Samuel Sela on defining features for feature-based design

• Basic concepts for FeatureCAM came from talking with Russ Fish on how to automate “Parts on Demand System”

• Concepts of using stock and part is what is left after subtracting manufacturing features.

• Work with Chi Cheng Ho and Beth Cobb on making manufacturing features.

Modeling and Manufacturing Air Force Parts -- F4 Sway Brace

None of the Air Force drawings were technically correct

1993 Modeling and Manufacturing

First Complex Assembly

Front Upright, Spindle, Hub, Caliper, Brake Rotor for Mini-Baja

Went together with no rework, forever proving the value of manufacturing from solid models

Early 90’s--Work with DARPA on Modeling and Manufacturing Diesel Engine

• Major modeling effort with many of the Alpha_1 staff involved in modeling different parts. Made animated video of running engine

• Made 1/3 scale model using Stereo Lithography Rapid Prototyping

• Machined 1/3 scale model from Aluminum• Part way thru, DARPA wanted it to actually run.

Made it run on compressed air

Collaborative Work with DARPA

• ~ 1995 – Early use of web-based collaboration with Stanford and others (Michigan State?, Cornell?) to design and build electro-optical tracker

Collaborative Work with UNC and Henry Fuchs

• Optical Sensor Ball• Multiple Camera System for Video

Conferencing• Plastic Mold for Stereo video/optical head

mount display for surgery• Multi angle mirror device

1996 -- More ComplexModeling and Manufacturing

Final Drive for Formula SAE

First Use of Wire EDM to cut splines and gears

More Gear and Splines

FormulaSAE Intake Manifold

Made wax cores using FDM Rapid Prototyping Machine. Cores wrappedwith composite. Wax melted after compositewas cured

Manufacturing a FormulaSAE Carusing Alpha_1 and FeatureCAM

2006 Car with the Team Captain

• Composite Chassis• Wheel Centers• Front and Rear

Suspension with integrated brakes

• Final Drive with quick change Gears

• Intake Manifold• Gear Shifter• Throttle Body

Alpha_1/FeatureCAMParts

Drilling for OilDiamond Drill for high speed drilling

Modeled from “napkin sketches plus cutter locations

New Design with rotating cutters

Multi-Mode Microwave Antenna for L3 Comm

Replaced 44 parts with 3 parts by realizing the desired shape was a ruled surface that could be cut with a 4-axis wire EDM

Full Scale Diesel Engine Parts

Current Work using FeatureCAM