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An Informal Introduction on Mechanical Design and Manufacturing
Dr. M. Mert Ankaralı Desisted Robotics Corp. & Middle East Technical University
Department of Electrical and Electronics Engineering, Middle East Technical University, November 30, 2016
What is my (academic) story?
Assistant Professor(?), METU Electrical & Electronics Eng.
PhD from JHU Mechanical Engineering
MS from METU Electrical & Electronics Eng.
BS from METU Mechanical Engineering
Design Process (OL)
Ideas, requirements Design (CAD)
Component/material selection Manufacturing
Assembly Product/Prototype
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Ankarali et al. 2011 & Saranli et al., 2011
Design Process (CL)
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Ideas, requirements Design (CAD)
Component/material selection Manufacturing
Assembly Product/Prototype
Feedback reduces
uncertainty
Design (CAD)
• USE CAD software • If your design looks good, then your final product will
probably be good
CAD designs by Dr. Alican Demir
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Epoxy
Shell heat-shrink
Signal and Groundwires
± 5V supply wires
Main cable bundle
PCB heat-shrink
Circuit board
Graphite shellBNC plug RCA plug
Silver PCB-Shellconnection
Epoxy + 5V
– 5VHigh torque servo motor (Hitec HS-325HB)
Adjustable Battery fixtureLithium Polimer Battery (Pro-Lite V2)
Servo Motor Controller (by Parallax inc.)
RF tranceiver & Serial adapter (xBee 1mW) (by Parallax.inc)
Quadrotor(X-3D-BL ResearchPilot by Ascending Technologies)
Design (CAD)
• Take advantage of open source CAD drawings of the commercial components
• Improve/update your design considering the other steps
CAD designs by Dr. Alican Demir
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Epoxy
Shell heat-shrink
Signal and Groundwires
± 5V supply wires
Main cable bundle
PCB heat-shrink
Circuit board
Graphite shellBNC plug RCA plug
Silver PCB-Shellconnection
Epoxy + 5V
– 5VHigh torque servo motor (Hitec HS-325HB)
Adjustable Battery fixtureLithium Polimer Battery (Pro-Lite V2)
Servo Motor Controller (by Parallax inc.)
RF tranceiver & Serial adapter (xBee 1mW) (by Parallax.inc)
Quadrotor(X-3D-BL ResearchPilot by Ascending Technologies)
Component/material selection
Probably, it won't work
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Component/material selection
Now, it may work
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Component/material selection
Have ever seen this ?
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Component/material selection
Most convenient type of ball bearings
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Component/material selection
Example ball bearing unit mounting
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Component/material selection
Alternative: Custom bearing/ball bearing housing May require some gluing
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Manufacturing
3D Printer: It’s a huge privilege for you, so use it
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Manufacturing
• Design for 3D Printer
• Part orientation is important • Minimization of support material • Inclusion of undercuts and other
manufacturing constraining features • Reduction of part count in assembly
Courtesy of Dr. Ulas Yaman
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Manufacturing
• The build on the left can be broken into the two builds on the right, which may be stronger and can be assembled together later
• Note the reduction in the amount of support material and the reduced build height
Courtesy of Dr. Ulas Yaman
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
ManufacturingProduct/
Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
• Material properties
• Good enough for many applications • Secret trick
• Soak the 3D printed part into a super glue (loctitie) pool and you will obtain a stronger material
• Note that holes and other passages will be (partially) filled with glue. Thus, design your part considering this and you may need to to some cleaning
Manufacturing
Courtesy of Dr. Ulas Yaman
Sheet cutting: Laser or water-jet
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Manufacturing
Courtesy of Dr. Ulas Yaman
Common materials: Plexiglass (acrylic), polycarbonate (lexan), aluminum, wood, …
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Sheet cutting: Laser or water jet
Manufacturing
A sturdy structure design method based on sheet cutting
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
ManufacturingProduct/
Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Machining (Hand or CNC): Turning & Milling
ManufacturingProduct/
Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Machining (Hand or CNC): Turning & Milling
Sometimes machining is unavoidable
Assembly
This is NOT an assembly tool Use these folks instead
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
Assembly
Is there a way to build structures with minimal amount of manufacturing?
YES: T-slot framing (a.k.a LEGO for engineers)
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
AssemblyProduct/
Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
• Widely used for industrial and hobby robotics and similar applications
• Can build giant structures as well as miniaturized ones
• They are precise and strong enough to build real machines
T-slot framing
AssemblyProduct/
Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
• T-slot systems consists of square extruded aluminum beams, various special connectors and the hardware
• The modularity is based upon the T-slot concept of their profiles
• The “T” shaped slots present on all sides, allow for infinite positioning along the axis.
AssemblyProduct/
Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
T-slot framing example connections and topologies
T and L shaped corners Motor mounting
T-slot + 3D Printing Enclosures
Quiz ?
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
What is the trick for increasing the material strength of 3D printed parts ?
Questions
Product/Prototype
Component/MaterialSelection
ManufacturingDesign (CAD) Assembly
IdeasRequirements
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