Contact info:
Teaching Assistant: Dan Chang (ychang253@wisc.edu)
Project description:
The semester project involves iterating through the design of a part or assembly, using any of the AM technologies available in the Makerspace. The goal is to use the knowledge acquired in class. You will be required to submit a project proposal, at least 1 project update, and a final report. This is a group assignment, with groups of up to 5 students.
Project proposal and updates will be posted as blog entries in UW Madison’s Additive Manufacturing blog. Review entries from previous semesters for ideas on how to make a cool post! Please exploit the advantage of uploading images and videos to make it easy for a reader not familiar with your project to follow along.
Instructions:
1) Form groups of 3-5 students in Canvas.
2) Select one person to be in charge of posting in the blog. This person will be granted publishing privileges in the blog.
3) Report on the progress of your project using blog posts. You are required to produce 3 blog entries: a project proposal a project update and the final report. If you deem it necessary, you can post additional entries, just make sure you have 3 posts that satisfy the criteria set in the project timeline.
• Please come up with a tag or category that describes your project and use it in all your blog posts to make it easy to find.
4) Submit a final project report summarizing your project (blog entry + word document). The word document report must not exceed 10 pages and must follow the SPE ANTEC formatting guidelines.
The project will have 3 deliverables. See below for more information.
Deliverables:
1. Project proposal (03/02/22)
– Title of your project
– Brief explanation of project: What is being done? Why?
– Preliminary designs and manufacturing considerations: Preliminary part drawings or STLs. Preliminary selection of material and AM technology to be used based on the aim of the project.
– Proposed first print trial, experiments, or similar: Try to think ahead and prepare a course of action to properly execute your project. As an example, here are some unknowns that could pose problems to your project, and need to be answered through print trials or experiments: What’s the minimum feature size we can reproduce? Can I produce this part without support? Can the assembly be printed in one go or do we require multiple prints? what material properties do I need (thermal, mechanical, color, transparency, medical grade…)? Additionally, consider other steps that are necessary for the project’s success that may not be directly related to AM. For instance: part measurements, use of 3D scanners, post processing, etc.
Feedback from TA on the project proposal will be sent. You may begin your trials and experiments immediately after. Between this date, and the first project update, machine time will be limited to 8 hours per print. This will force you to carefully optimize your print time. Consider manipulating print parameters, or using other resources, such as topology optimization.
2. Project update (04/06/22)
Execution of print trials and experiments proposed. Carefully document the results of what you proposed during the project proposal phase. This includes pictures, data, mechanical drawings, etc. Were your experiments successful? Did the results merit a redesign or a reconsideration of the part design, material, or even the chosen AM technology? Include the print time of each print you performed. Indicate how you will improve the design of your part based on what you have learned up to this project report.
3. Final report (05/04/22)
This report needs to be formatted using the SPE paper guidelines (see SPE format document in Canvas). Document must not exceed 10 pages. Summarize the project proposal, trials and results in formal terms.
Grading remarks:
You will lose 5 points per day for late deliveries, with a maximum penalty of 15 points. No report will be accepted past 3 days of the proposed delivery date, effectively rendering the grade for the assignment as null.
Suggestions:
– You can pick something that is applicable to your research, senior design project, or extracurricular activities! If you are having trouble thinking of something, talk to Prof. Osswald or the TA.
– Some slicing engines are available online for free, including Cura (for FFF) and PreForm (for SLA). You can experiment with the slicing in your own computer to save time. Make sure you select the printer you intend to use in the software, so the available build volume is correct.
– You can use the makerspace to print your parts (use the ME514 account to pay for your parts). You will need to schedule an appointment online. You will need to plan ahead as the slots might fill out fast.
– There is a limit on the fund destined to ME514 Makerspace prints, so please be mindful of others and avoid doing unnecessary prints.
– Posting in the blog from an outside network may require access to the VPN. To avoid headaches, plan to post within UWNet or use the WiscVPN.