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:

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

A Large Plug For A Famous Hand!

Everyone at Coastal Enterprises Company liked this previous story so much we decided to share it again for our newer readers! Who do you call if you’re a discerning family-themed cruise line looking to build a state of the art water slide featuring a signature element from one of your most beloved and iconic characters? The answer is FormaShape 3D Architectural Design Solutions of British Columbia. The design called for a giant replica of the white-gloved hand from everyone’s favorite cartoon mouse supporting the main structure of the slide. Patrons had to immediately recognize the hand, so every detail of the larger-than-life appendage became important, right down to the fingers, 3 of them, and thumb….good trivia question!

Because of its strength, rigidity and ease of machining, FormaShape chose to machine the FRP tooling plug from Precision Board Plus (both PBLT-4 and PBLT-8). Once the CAD design was approved by the client, the toolpath was fed into their 5-axis CNC router to machine the segmented plugs that made up the hand. According to Sean Conneely, Custom Fabrication Manager at FormaShape, new systems were developed for both the segmented plug and moulding techniques used on this project. In addition, special fabrication techniques had to be developed for both the plug and moulded parts. The precise Open Moulded process used by FormaShape ensures that the final FRP panels that make up the finished hand are within +/- 1mm of the Precision Board Plus machined plug!

Having designed, engineered and manufactured the entire slide, the job of installation naturally fell to FormaShape – Whitewater West Industries. Check out their websites at www.formashape.com and www.whitewaterwest.com for more examples of their work.

Family-Themed Cruise Line Debut’s New Water Slide

Who do you call if you’re a discerning family-themed cruise line looking to build a state of the art water slide featuring a signature element from one of your most beloved and iconic characters? The answer is FormaShape 3D Architectural Design Solutions of British Columbia. The design called for a giant replica of the white-gloved hand from everyone’s favorite cartoon mouse supporting the main structure of the slide. Patrons had to immediately recognize the hand, so every detail of the larger-than-life appendage became important, right down to the fingers, 3 of them, and thumb…..good trivia question!

Finished Precision Board Plus plug showing bonded segments used to construct the machining block

Because of its strength, rigidity and ease of machining, FormaShape chose to machine the FRP tooling plug from Precision Board Plus (both PBLT-4 and PBLT-8). Once the CAD design was approved by the client, the toolpath was fed into their 5-axis CNC router to machine the segmented plugs that made up the hand. According to Sean Conneely, Custom Fabrication Manager at FormaShape, new systems were developed for both the segmented plug and moulding techniques used on this project. In addition, special fabrication techniques had to be developed for both the plug and moulded parts. The precise Open Moulded process used by FormaShape ensures that the final FRP panels that make up the finished hand are within +/- 1mm of the Precision Board Plus machined plug!

Precision OM process used to manufacture the FRP segments that make up the hand

FormaShape attaching the slide flume to the supporting hand

Did you know Coastal Enterprises makes support fixtures?

Coastal Enterprises will fabricate a support fixture for any Precision Board Plus tool. This support tool can be used for tool transport, CNC machining, lay up of composite laminate, oven/autoclave curing, final inspection, and every other process procedure. Support structures are designed with all-direction casters, leveling jacks, and tool hold down attachments that can be tightened during machining, etc. and loosened during oven/autoclave cycling. The custom hold down attachment allows independent movement between the tooling block and the support fixture.

Call us at (800) 845-0745 for more information or send us drawing of your tool.

Even the Art is Big In Texas: The Aggie Ring

A 3D laser scanner that is accurate to 1/100^th of an inch and a 3 axis CNC mill capable of sculpting an 8 inch thick 4’x 8’ block of material are not the typical tools you find in an art studio. But then this is no ordinary art studio. It’s Blue Genie Art Industries of Austin Texas and they are the fabricators of the model that was used to cast this 12 foot high bronze replica of the coveted Aggie ring that now adorns the entry of the newly refurbished Alumni Center at Texas A&M University in College Station Texas.

Each element of the highly symbolic ring was reproduced in great detail by the artisans of Blue Genie. Using a digital model supplied by ring maker Balfour, they were able to “scale up” the rendering to the massive dimensions of the project, maintaining all of the fine detail of an actual ring. With the help of , “toolpaths” were created for their milling machine to follow. Using 8lb Precision Board Plus (PBLT-8), sections of the ring were milled with every intricate detail of this Aggie icon. The sections were then assembled and bonded to a custom eight foot diameter steel-fabricated armature to create the model.

According to Kevin Collins, one of Blue Genie’s Principles, “This was a challenging project for Blue Genie, requiring the right combination of artistry, technology and materials. Using PBLT-8 Precision Board Plus was an integral and sound decision in holding the details of the class ring, and a great choice for CNC milling, sanding and finishing to a mold ready surface for the bronze foundry process.”

The project was then turned over to Deep in the Art Foundry of Bastrop, Texas to take the molds and perform the bronze casting and fabrication of the 6500lb replica of Aggie pride. According to Clint Howard, Deep in the Art’s President, “compared to other big projects we’ve done, this is technically the most challenging piece when it comes to surface finish”. Although the ring was cast in sections and then welded together, all the effort put into grinding and polishing makes it appear that the giant ring was cast as one solid piece. After all, the larger than life example had to live up to the symbols of integrity, achievement, power and valor, which are just a few of the many traits the ring has come to represent to Aggie alumni.

As an inspirational gesture, a time capsule was fabricated into the bezel of the ring, which will be opened by alumni in 50 years. For more on the Haynes Ring project and the Aggie tradition, see the video A Ring for All Aggies.

Did You Know?

Precision Board Plus is non-abrasive and can be machined and cut with HSS cutters, or any standard cutting tool. In addition, Precision Board Plus does not out-gas during the curing process, so it’s ideal for prepreg layup tools and mold patterns (see autoclave ramping procedures). To learn more about the capabilities of Precision Board Plus, view or download our product data sheets.

Need help with a quote? Click here or call us at 800-845-0745