Design For Manufacturability in the Architectural Field

Having a vivid imagination in the design world is an asset, but being able to realistically apply it in the real world is a learned skill.

Within the Department of Architectural Technology at the New York City College of Technology (CUNY) , the Introduction to Computation and Fabrication course aims to teach students introductory CNC techniques, with added focus on Design for Manufacturability.

Using parametric software such as Grasshopper in combination with RhinoCAM, students are taught to create their own tool paths. These tool paths are then “proofed” on a CNC machine using a variety of materials, such as Precision Board, to analyze the design for imperfections or errors.

If the student has designed a complex tool path with many tight, narrow valleys, they may realize as a consequence that the machining time is far too long – with the result being a design that no customer could afford.

If the tool path proves successful, the design is then produced on materials including Precision Board Plus HDU. The goal of this is to teach students that when they design something, they should also have a pretty good idea of the output technology required to bring their design to life.

Additional information on the Introduction to Computation and Fabrication course, taught by prof. Anne Leonhardt and Zach Downey, can be seen at: http://openlab.citytech.cuny.edu/compfab/.

Brian Ringley, Technology Coordinator for the National Science Foundation ATE Fuse Lab grant program which initiated the course, sent us pictures of several projects featuring Precision Board donated by Coastal Enterprises from their exhibitions.

These pictures show student-created projects made using Precision Board Plus PBLT-4, PBLT-6 and PBLT-8 for the Intersections 2013 exhibition:

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This project was created by esteemed artist and designer Francis Bitonti as part of a student-artist collaboration exhibit called “Intersections” held in 2012. The project is titled the “Schistose Mirror” and shows Precision Board Plus PBLT-10 mounted onto Trupan MDF being cut on a CNC router. After it was CNC cut it was professionally painted by an auto body shop. See more work from Francis Bitonti at: http://francisbitonti.com

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The Bank Job: Everything’s Bigger in Texas!

The state’s big, the barbecue is big, and the sign hanging at the Federal Reserve Bank of Dallas is absolutely massive. This enormous sign was built by Museum Arts, Inc., and according to Chris Shin, Head of the Fabrication Dept. at Museum Arts, was one of their most challenging projects.

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Measuring in with a 17′ diameter, this sign required a custom structure just to get it out of the dang building! Crafting this beauty was no easy feat either. The majority of the sign was made with CNC routed sections of 4″ x 4′ x 8′ Precision Board Plus PBLT-15. In addition, to make sure this hanging giant would maintain integrity, a huge aluminum frame was welded together and attached to the back of the HDU with epoxy.

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For additional protection against the elements, a 2-part bedliner was sprayed onto the Precision Board, creating a strong, weatherproof (and heavy-duty!) surface.

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Since you can’t always find Paul Bunyan to hang your sign when you need him, engineers hired by the Bank, along with employees from Museum Arts performed the herculean feat of mounting this sign. The installation was a great example of modern engineering with a pulley system and several guys on the roof and below the sign working together to secure it to the wall.

Needless to say, this big sign gets some major accolades from Coastal Enterprises on its beautiful appearance!

A big thanks goes to Todd Kriechbaum at Port Plastics for sending us these pictures and supplying Museum Arts with Precision Board Plus.

More info about Museum Arts can be seen at: http://museumarts.net

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Racing In The Mud: The Baja SAE Experience

As far as school clubs go, it doesn’t get much cooler than the Baja SAE off-road vehicle team. Earlier in the year we wrote about Cal Poly Pomona and the rugged BAJA SAE car they built for this year’s competition. We have since been in touch with Jessica Ghareebo, Cal Poly Pomona Baja SAE President, who was able to update us on what makes the 2013 vehicle tick.

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The goal of this year’s project was to lower the car’s center of gravity and decrease total vehicle manufacturing time by 30%. To start, students created a vehicle model in SolidWorks and analyzed it for aerodynamics. After finalizing the design, CAD models were sent to local company ADM Works, who donated time on their massive CNC machine to cut out molds using Precision Board Plus donated by Coastal Enterprises.

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After receiving the machined molds, they were primed and sanded to a smooth finish. Students then applied a mold release before creating negative molds using a fiberglass layup technique. Finally, carbon fiber was laid up onto the fiberglass to create the finished body panel part. All molds for the body panels were made using Precision Board Plus PBLT-6, while PBLT-40 was used to create the mold for the fuel catch.

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According to Anthony Cerrato, Electrical and Composites Captain, “Working with Precision Board saved the team a lot of time. After receiving the molds back from ADM Works, the cuts were so clean that finishing time was reduced.” At the time of competition, the project goals of lowering the vehicle’s center of gravity and decreasing manufacturing time by 30% were successful.

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The Baja SAE competition is quite popular among university/college students. Many, many teams compete in the strenuous competition that includes uphill races and rock crawls. Cal Poly Pomona managed to do quite well in both competitions, placing 11th overall out of 100 teams in the Baja SAE East competition, and 6th overall out of 87 teams in the Baja SAE West competition. Coastal Enterprises would like to congratulate all students involved and wish them luck again for next year!

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A Sign Is The Welcome Mat For A Business

Having a nice sign at a restaurant is imperative – it is the welcome mat for passersby and one of the best representatives of the business.

Vic Holt, owner of Rev Art in Decatur, AL sent in some pictures of a sign he made for the “Back Alley Bistro“, a restaurant also located in Decatur. When the customer came to him wanting an old-fashioned looking sign but with a modern edge for their business, Vic knew he could create the sign desired using his CNC router coupled with Vectric Aspire CNC Software.

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Using Precision Board Plus PBLT-15, Vic used his CNC machine to carve the double-sided sign before priming it using FSC-88WB Primer/Filler. After the primer, Vic applied the initial paint coat, starting with the color which belonged in the deepest recesses of the sign. Using a combination of rollers, foam brushes and bristle brushes, Vic applied separate colors of Sherwin-Williams Exterior Latex/Acrylic, using a foam roller on the highest parts of the sign while taking care not to over-saturate the roller to avoid drips.

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After the paint is complete and the sign is installed, Vic makes an on-site visit to inspect for any imperfections that might require touch-ups which may be more easily visible in the sunlight. Giving his customers the best is not enough – his goal is to ensure his customers are permanently satisfied with his work.

Be sure to visit: http://www.rev-art.com for more info!

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University of Nevada’s Concrete Canoe Races To A Win!

Practice makes perfect as the University of Nevada Concrete Canoe team “Dambitious” paddles to an overall win in this year’s regional concrete canoe challenge known as the Mid-Pacific Conference.

The University of Nevada team finished first place in all 5 races in the competition that took place at Vasona Lake in Los Gatos, CA on April 19th. Individual events included men’s and women’s sprint (200 meters) and endurance races (600 meters), with the final race being a 400 meter co-ed race.

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We had the opportunity to speak with Alicia Veach, Project Manager for the University of Nevada canoe team this year, about just how they were able to finish with such high standings. Alicia attributed the win to their practice regimen and a very well designed canoe hull. The mold for the canoe was made from Precision Board Plus donated by Coastal Enterprises.

The competition-winning hull was created by analyzing different hull designs using a unique Excel program called Aqua-holic, which was developed by the 2008 U of N team. Theoretical results based on submerged shape, length and beam evaluated straight line speed. An empirical equation in the spreadsheet estimates the time required to complete a 180-degree turn. Ducimus, the 2012 team, was selected as a preliminary hull design because it had the greatest top speed and the second fastest turning time compared to four previous Nevada canoes. (Courtesy University of Nevada Mid-Pac Research Paper).

After selecting the Ducimus hull, changes were made to improve straight line speed and manueverability, thus creating the 2013 “Dambitious” canoe design. After the design was finalized, Precision Board Plus PBLT-4 HDU was CNC machined to create a mold (To see the mold being machined click here). Concrete was then poured into the mold and allowed to cure for 28 days before being released from the mold.

In the past, cutting the canoe free from the mold has not been an easy process. This year however, the Nevada team constructed an innovative air release system. Team members drilled two holes through the form at each transverse rib location. Each of the eight air ducts were then connected using PVC pipes. The end result was the introduction of air into the system provided enough pressure to release the canoe from the form.

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The next step was a lengthy period of sanding, starting with 80 grit and working up to 1000 grit, until the desired shape was attained. Numerous items such as wooden blocks and shop lights were used to locate high and low spots and ensure even sanding.

After the sanding was complete, the final step was making it an aesthetically-pleasing product. Non-toxic, eco-friendly concrete stains were used for the majority of the finish while an air brush and stencils were utilized to apply the graphics.

Winning first place overall doesn’t just depend on winning all the races either (which seems like a pretty big feat anyways!), there are 4 categories that make up placement score:

  • Races – 1st Place
  • Design Paper – 1st Place
  • Final Product Score (canoe finish, concrete samples, display)  – 1st Place
  • Presentation – 3rd Place

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Coastal Enterprises would like to congratulate the entire Concrete Canoe team at the University of Nevada on their win! They now move on to the National Competition which will be held at the University of Illinois at Urbana-Champaign, Urbana, IL from June 20-22.

To see why they race concrete canoes (and more of how the U of N built their canoe), visit our previous blog: Racing Concrete Canoes Part 1.

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