BY CHRISTOPHER F. SIKORA
© Copyright 2013 Christopher Sikora
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Rhino 3D is a registered trademark of Robert McNeel & Associates.
Other brand or product names are trademarks or registered trademarks of their respective holders.
The information discussed in this document are subject to change without notice and should not be considered commitments by Christopher F. Sikora. The software discussed in this document is furnished under a license and may be used or copied only in accordance with the terms of this license.
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Rhino 3D is a registered trademark of Robert McNeel & Associates.
Other brand or product names are trademarks or registered trademarks of their respective holders.
The information discussed in this document are subject to change without notice and should not be considered commitments by Christopher F. Sikora. The software discussed in this document is furnished under a license and may be used or copied only in accordance with the terms of this license.
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CAD220 COURSE SYLLABUS
Rhino 3D
Course Description:
Industrial / Product Design (Rhino 3D) Basics 3 credit hours Exploration of the theory and application of Industrial Design, conceptual hand sketching and solid modeling techniques for industrial product design. Prerequisite: Intro to Engineering Drawings 101 or consent of instructor. (1 lecture hours, 2 lab hours) Course Objectives:
Provide the student with the knowledge and practical experience in the areas of Industrial / Product Design along with construction of 3D CAD modeling of parts, assemblies, and the creation of prototypes. General Course Outline
Date
Week Topic 1.
Introduction to the Interface Lecture (Exercise 1 - E1) Modeling Theory - Sketching and Base Feature Geometry Creation.
2.
Hand Sketching - Industrial Design Enhancement Project #1 (P1 Due 9/23/10)
3.
Introduction to Freeform Part Modeling (E2)
4.
Intro to 3D Printing/Lab time to work on (P1)
5.
Intro to surfacing and modeling an organic shape (E3)
6.
Industrial Design Enhancement Project #2 (P2 - Due 10/30/10)
7.
Creating Assemblies (E4). Review for Mid Term
8.
Mid Term Exam
9.
Curves and Sweeps (E5)
10.
Lab time to work on (P2)
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11.
Industrial Design Enhancement Project #3 (P3 - Due 11/23/10)
12.
Introduction to Photo-Realistic Rendering
13.
Industrial Design Enhancement Project #4 (P4 - Due 12/10/10)
14.
Project (continued)
15.
Lab time to complete exercises, Review for Final Exam
16.
Final Exam
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EXERCISE 1
Basic Solid Modeling (60 pts.) This lesson is a basic introduction to the Rhino Solids capabili ties. . Objective: Create a flashlight derived from hand sketches.
1.
Go to file/new and select the Inch template. Save it as CE1.
2.
Select the Polyline segment icon with the left mouse button.
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3.
Zoom out on the “Top” view to allow at least 10, 1” grid blocks to fit in the screen.
4.
Draw the sketch below. Use the grid and snap option.
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5.
When finished Right Mouse Button (RMB) click on the “Solid” icon. This will bring up additional options to select from. Find the Extrude closed planar curve icon. And LMB click on it.
6.
Select the sketched profile and hit the “Enter” key. Drag it out on the “Right” view approximately 1.5” with the “BothSides” option used.
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7.
Using the Polyline icon again, draw a handle profile on the “Top” view.
8.
Use the Solid extrude feature again. Extrude it only .5”.
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9.
RMB on the Boolean icon to locate the fillet tool. Use .5”. Add them as seen below.
10.
Add .375” fillets as seen below.
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11.
Add .125 fillets to finish the handle.
Performing a Boolean Union 12.
Select the Boolean Union icon and then select both the body and handle sections.
13.
Add .06” fillets to the intersecting edges between the body and the handle.
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14.
At any time you can reset your view orientation by RMB clicking on the “Set View” icon, and choosing a view.
Adding Embossed Text 15.
Select the Text icon. Type in your text and hit “OK”. Enter 1” for Height and .06” for the thickness.
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16.
Click to drop the text on the Top view.
17.
Window around the letters to merge into a group. Select the “Group” icon.
18.
Select the text and drag it (with snap on) to the Top surface of the Flashlight.
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Objective: Redesign the stapler to enhance its appearance and try to include new ideas to enhance the overall product. Create a presentation and be prepared to sell your concept to the class. You will be awarded points on the following:
Appearance 20pts. Functionality 20 pts. (Supply sketches, CAD drawings, and or renderings) Analysis (Mechanical and Marketing) 20 pts. Presentation 40 pts.
Total Contract Award: 100 Points max. rd Due: Wed. Sept. 23 . Samples:
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Harris Profile
(Source: Wikipedia)
Method for assessing a design A new product profile (or Harris profile) is a graphic representation of the strengths and weaknesses of design concepts. Originally, a new product profile is applied as a useful tool to evaluate and select development projects (ideas for new business activities). But this method can also be used t o evaluate and decide in later phases of product development. Per design alternative a Harris profile is created. A number of criteria are used to evaluate the design alternatives. A four-scale scoring is used for all criteria. The decision maker should him/herself interpret the meaning of the scale positions (i.e. -2 = bad, -1 = moderate, etc.). Because of its visual representation, decision maker(s) can quickly view the overall score of each design alternative on all the criteria, and compare these easily.
CONCEPT 3 SAFE FORM STABLE STRONG COMPACT COLOR STYLE FUNCTION TEXTURE WEIGHT
-2 -1
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CONCEPT 2 SAFE FORM STABLE STRONG COMPACT COLOR STYLE FUNCTION TEXTURE WEIGHT
CONCEPT 1 SAFE FORM STABLE STRONG COMPACT COLOR STYLE FUNCTION TEXTURE WEIGHT
-2
-1
1
-2
-1
1
2
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EXERCISE 2
I ntroduction to F reeform Modeling This lesson is a basic introduction to the Rhino Freeform capabilities .
Objective: Create a flashlight using freeform tools.
1.
Go to file/new and select the “Small Object Inch” template. Save it as CE2.
2.
Select the Curve: interpolate point’s icon with the left mouse button.
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3.
Zoom out on the “Right” view to allow at least 6, 1” grid blocks to fit in the screen.
4.
Draw the sketch below. Use the grid and snap option.
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5.
On the “Top” view draw the sketch below. Use the 3- Point arc tool (RMB to access option) with the grid and snap option.
6.
Select the “Mirror” icon. Select the arc then hit enter, and then draw a vertical center at the origin.
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7.
Using the Polar Array icon to create a copy 270◦ rotated around the “Front” view origin.
8.
Use the Surface/Loft feature. Be sure to select all c urves and the “Closed Loft” option.
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9.
Surface Patching: RMB on the Surface icon to locate the Patch tool.
10.
Change dialog box values as seen below. Select the open back edge
11.
Select the “Join” icon, and then select both surfaces. Hit enter.
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12.
Capping a planar hole: RMB the “Solids” icon, and locate “Cap”. Select the surface body.
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EXERCISE 3
Modeling a Pumpkin This lesson explores one way to make a pumpkin . Objective: Create a pumpkin using the freeform tools inside Rhino.
1.
Go to file/new and select the Inch template. Save it as CE3.
2. 3.
Draw a circle on the “top” view. This is used for approximating pumpkin dia. Select the Curve: interpolate points icon with the left mouse b utton.
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4.
Draw the spline around the circle as shown. Delete the circle when done.
5.
Use the Scale tool to make four smaller profiles centered. Select the profile. Then click in the center of the profile for location.
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6.
On the “Top” view select the sketch profile. Be sure to activate the copy with typing in “Copy” in the command line.
7.
Move the smaller pairs of profiles above the “ Top” view and the larger profiles below.
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8.
Use the surface loft tool.
9.
Select the five profiles in order.
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10.
Draw two guide rail curves as shown on the “front” view. RMB on the Surface icon to locate the Patch tool.
11.
Use the Sweep with 2 Rails surface option. Select the two rails and inner pumpkin profile.
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12.
Apply lights, material and a base. Then render.
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Objective: Redesign the cell phone to enhance its appearance and try to include new ideas to enhance the overall product. Create a presentation and be prepared to sell your concept to the class. You will be awarded points on the following:
Appearance 20 pts. Functionality 20 pts. (Supply sketches, CAD drawings, and or renderings) Analysis (Mechanical and Marketing) 20 pts. Presentation 40 pts.
Total Contract Award: 100 Points max. th Due: Wed. Oct. 30 . Samples:
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EXERCISE 4
Modeling a Bottle and Cap This lesson explores one way to make a bottle assembly . Objective: Create a bottle using the freeform tools inside Rhino.
1.
Go to file/new and select the Inch template. Save it as CE4.
2. 3.
Draw a following profile on the “front” view. Join the curves when done. Use the interpolate points tool for the neck and base transition. Use tangency.
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4.
Use the Surface, Revolve tool to create the bottle.
5.
Draw the cap profiles using two separate interpolated curves.
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6.
7.
Use the Surface, Sweep with two rails. The two curves will be the rails and the edge of the bottle will be the cross section curve.
The cap should be finished.
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7.
Add model materials, lights and base then render.
EXERCISE 5
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Modeling a F reeform Bottle This lesson explores one way to make a bottle. Objective: Create a bottle using the freeform tools inside Rhino.
1.
Go to file/new and select the Inch template. Save it as E5.
2. 3.
Draw a following profile on the “front” view. Join the curves when done. Use the interpolate points tool for the neck and base transition. Use start and end tangency. Mirror.
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4.
Activate the Analysis toolbar, Select the Geometric Continuity icon. Then select the two curves close to the junction. Continuity – The smoothness at a junction between two curves or surfaces. Position - Position continuity (G0) Position (G0) continuity means that the end points of a curve or the edges of two curves or surfaces touch each other. End control points are at the same location. Tangent - Tangent continuity ( G1) Tangent (G1) continuity means that the tangent direction of the two curves or surfaces is the same. Fillet arcs form this kind of continuity with the lines or surfaces filleted. The two control points of the arc and the adjacent curve line up. Curves and surfaces with G1 continuity are als o G0 continuous. Curvature - Position, curvature, and tangency match ( G2) Curvature (G2) continuity means that the tangent di rection and the curvature of the two curves or surfaces is the same. Blend, BlendSrf, Match, and MatchSrf form this kind of continuity. Three control points of the blend and the adjacent curve line up (up to degree 3 curves). Curves and surfaces with G2 continuity are a lso G1 and therefore
G0 continuous .
Source: R hino 3D Help
5.
Draw the guide rails using two separate interpolated curves.
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6.
7.
Use the Surface, Sweep with two rails. The two curves will be the rails and the edge of the bottle will be the cross section curve.
The cap should be finished.
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7.
Split and Delete the excess surfaces.
8.
Sketch a concove spline between the opening at the bottom. Use the Sweep with two guide rails.
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9.
Sweep with two guide rails.
10.
Patch the top and bottom openings. Cut handle hole. Add fillets and neck.
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Objective: Redesign the wrist watch to enhance its appearance and try to include new ideas to enhance the overall product. Create a presentation and be prepared to sell your concept to the class. You will be awarded points on the following:
Appearance 20 pts. Functionality 20 pts. (Supply sketches, CAD drawings, and or renderings) Analysis (Mechanical and Marketing) 20 pts. Presentation 40 pts.
Total Contract Award: 100 Points max. th Due: Wed. Nov 30 . Samples:
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“Use this project or come up with your own idea for Project IV!”
Part design for Thermoforming
What is thermoforming? Thermoforming is a manufacturing process for thermoplastic sheet or film. Specifically, it is more of a converting process, where plastic sheet or film is converted into a formed, finished part. The sheet or film is heated in an oven to its forming temperature, then stretched into or onto a mold and cooled. Early generation thermoforming machines usually incorporated cal-rod type heaters, similar to heating elements found in conventional electric kitchen ovens. These are still used, but more modern equipment frequently uses quartz heaters or radiant-panel heaters for more efficient sheet heating and ease of zone control. Cast or machined aluminum is the most common mold material, although epoxy, wood and structural foam are sometimes used for prototypes, samples, and low volume production runs. Aluminum molds are normally water-cooled by a cooling tower or chiller system for faster production capabilities. Thermoforming differs from injection molding, blow molding, rotational molding, and other forms of processing plastics, and is primarily used in the manufacture of disposable cups, containers, lids, trays, blisters, clamshells, and other products. A thermoform machine can utilize vacuum only, or vacuum combined with air pressure, in the forming p rocess. It can be as small and simple as a table-top sample former where small cut sheets of material are placed into a clamp and heated and formed, or as large and complex as a complete inline extrusion, thermoforming, trimming, granulating, and material handling system for continuous high-speed production. Many thermoforming companies do not
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